KR20050075752A - Method and apparatus for making interlabial pads - Google Patents

Abstract

The invention is directed to method and apparatus for making pads, such as interlabial pads. The apparatus includes a blending apparatus that weighs and blends fibers of different materials, at least one of which is absorbent. The blended fibers are conveyed through a chute to a fiber collection station. At the fiber collection station, collecting and feeding apparatus collects the blended fibers and feeds them to a forming apparatus that forms the blended fibers into a continuous blended-fiber web. The blended-fiber web is fed to a pad-making apparatus that cuts fluid-absorbent bodies in the blended- fiber web and laminates the bodies with at least one continuous cover web to form a laminated web. The laminated web is fed to a sealing and cutting apparatus to make the pads. Folding apparatus is provided for folding each pad along a major axis thereof.

Description

METHOD AND APPARATUS FOR MAKING INTERLABIAL PADS}

The present invention relates to a method and apparatus for manufacturing a pad, and more particularly, to a method and apparatus for manufacturing a folded female protective pad. Methods and devices for the manufacture of women's protective pads generally include fiber mixing devices and methods, devices and methods for forming continuous webs with layers of mixed fibers, pads manufacturing devices and methods, pad folding systems and methods, pad wrapping Methods and apparatus are included.

The present invention provides commercial preparation of pads of the type shown in US Pat. No. 4,595,392, entitled "Interlabial Pads," and US Pat. No. 4,673,403, "Methods and Pads for Improving the Placement of Physiological Devices." Particularly suited to the above, both patents are assigned to Kimberly-Clark Corporation and incorporated herein. Pads disclosed in these patents generally comprise a laminate in which a layer of absorbent material (eg, a fiber blend comprising cotton fibers) is disposed between two cover layers, one of the cover layers being fluid permeable and pad Facing the body when used, the other cover layer is typically fluid impermeable. The pads are smaller than other women's protective products and must be manufactured with relatively precise tolerances. These size and tolerance requirements pose challenges in making this product effective and economical for commercial purposes.

1 is an illustration of one embodiment of an interlabial pad made in accordance with the apparatus and method of the present invention.

2 is a cross-sectional view of the pad of FIG.

3 is a view showing a folded state of the pad of FIG.

4 is a cross sectional view taken along the line 4-4 of FIG.

5 is a flow chart illustrating various sections of the manufacturing process of the present invention for manufacturing pads.

6 is a flow chart illustrating various components of one embodiment of a fiber mixing section of a manufacturing process.

7 is a front view of the metering device of the fiber mixing section.

8 is a schematic front view of the blend opener of the fiber mixing section.

9 is a schematic front view of the separator of the mixing section.

10 is a schematic front view of the fine opener of the mixing section.

11 is a side view of the feed chute of the fiber collection and feed section.

12 is an enlarged view showing the supply of the supply chute of FIG. 11 and the beater roll.

Figure 13 is a side view of the device in the fiber forming section of the present invention.

FIG. 14 is an enlarged view of a portion of FIG. 13 showing individual fibers “air laid” on a moving conveyor. FIG.

15 is a left end front view of FIG. 13;

Figure 16 is a schematic diagram showing the fiber forming section, pad making section, pad folding section, and pad packaging section of the present invention.

Figure 17 is a side view showing a web of mixed fibers compressed by a pressure roll.

18 is a schematic front view of the apparatus in the pad manufacturing section.

19 is a schematic diagram illustrating a laminated web through a sealing nip.

20 is a schematic front view of the knife roll of the first cutting station in the pad making section.

FIG. 21 is a partial sectional view showing the structure of the knife roll of FIG.

FIG. 22 is a schematic diagram illustrating a mixed-fiber web passing through a nip between a knife roll and a first transfer cylinder. FIG.

FIG. 23 is a partial cross-sectional view showing the compressible insert in the cutting blade on the knife roll of FIG.

Figure 24 is a front view of the first transfer cylinder, partially broken away to show the vacuum box inside the cylinder.

FIG. 25 is a sectional view taken on line 25-25 in FIG. 24, and FIG. 26 is a front view of the seal roll in the pad fabrication section.

FIG. 27 is a partial sectional view showing the structure of the sealing roll of FIG.

Figure 28 is a front view of the knife roll of the second cutting station in the pad making section.

29 is a front view of the device of the folded section and the packaging section.

30 is a perspective view of the device of the folded section.

Figure 31 is a front view of the pressing and folding disc of the folding section.

FIG. 32 is an enlarged vertical sectional view taken on line 32-32 in FIG. 29, showing the disk folded by the folding disk.

33 is a front view of the adhesive applicator in the folding section.

34 is a perspective view of a conveyor for transferring pads from a folding station to a packaging section.

35 is a perspective view of the device of the packaging section.

Figure 36 is a perspective view of a forming apparatus for forming a tube with a web of material around a pad that is sent to the apparatus.

37 is a plan view of the forming apparatus.

38 is a side view of the forming apparatus and associated components.

38A is a side view of a variant of the forming apparatus and associated components.

Figure 38B is a perspective view of the pressing plate for applying downward force on the pad as the pad moves across the forming apparatus.

FIG. 38C is an exploded perspective view of the pressure plate of FIG. 38B, showing air holes in the pressure plate. FIG.

FIG. 39 is a vertical sectional view taken on line 39-39 in FIG. 38;

40 is a vertical sectional view taken on line 40-40 of FIG.

Figure 41 is a perspective view of an endless belt for exerting a downward force on the pad as the pad moves across the forming apparatus.

42 is a perspective view of an applicator for applying an adhesive to a web as the web moves across the shaping device.

Figure 43 is a front view of the applicator of Figure 42;

FIG. 44 is a horizontal cross sectional view taken along line 44-44 in FIG. 43; FIG.

Figure 45 is a perspective view in an elevated position of the conveyor for transferring the wrapped pad from the forming apparatus to the sealing roll.

46 is a schematic plan view of a series of pads wrapped in a tubular wrapper.

47 is a perspective view of a sealing roll.

Corresponding reference characters indicate corresponding parts throughout the drawings.

The apparatus and method of the present invention provide an effective and economical pad manufacturing that includes, but is not limited to, relatively small pads (e.g., interlabial pads) of the aforementioned type requiring relatively tight manufacturing errors. do. Such devices and methods have several aspects.

In one aspect, the invention is generally an apparatus for manufacturing a folded interlabial pad, each having a fluid-absorbing body laminated with at least a first cover layer of fluid-permeable material. The apparatus comprises: a mixing device for mixing fibers of different materials, at least one of which is absorbent, and for conveying the mixed fibers to a fiber collection station, disposed in a fiber collection station, for collecting and feeding the mixed fibers to a forming station A collecting and feeding device, a forming device disposed at the forming station and for forming a continuous mixed-fiber web from the mixed fibers. The apparatus cuts the fluid-absorbing body in the mixed-fiber web, laminates the body with at least one continuous cover web to form a laminated web, and seals and cuts the laminated web to produce the interlabial pad. A pad-manufacturing device, a folding device for folding each pad along its major axis, and a wrapping device for wrapping each pad.

Mixing apparatus for mixing the first and second fibers is generally an apparatus for conveying a first fiber feed to a first weighing station, and a conveying second fiber feed to a second weighing station. It includes a device for. The mixing device also includes a first metering device disposed at a first metering station and for metering and releasing a first amount of first fibers, a metering device releasing and metering a second amount of second fibers at a second metering station. A second metering device, and a fiber opening and mixing device for opening and mixing the first and second amounts of fibers released from the first and second metering devices. The fiber opening and mixing device includes a housing having an inlet for entry of fibers and an outlet for release of fibers, and a beater roll rotatable within the housing for opening and mixing the fibers and discharging through the outlet ( and a blend opener with a beater roll. A fine opener of the opening and mixing device is provided with an inlet for receiving fibers from the blend opener, a housing having an outlet, and rotatable within the fine opener housing to further open and mix the fibers. And a clothing roll for ejecting through the outlet.

In another aspect, an apparatus for forming a continuous web with a layer of mixed fibers includes a mixing apparatus for mixing the first and second fibers, a collecting and feeding apparatus disposed in the fiber collection station. The collecting and feeding device is arranged at an inlet, an outlet for receiving a feed of mixed fibers, an accumulation chute for accumulating a column of mixed fibers and disposed between the inlet and the outlet, and at the outlet. Feed means for feeding the fibers from the column to the forming station as an initial layer of mixed fibers through the outlet. A fiberizing device is used to break the initial layer into individual fibers. The reforming apparatus includes a reforming conveyor on which the individual fibers are stacked as a reformed layer of blended fibers.

A pad manufacturing apparatus according to an embodiment of the present invention is a device for supplying a continuous fiber web to a first cutting station, cutting the fiber web disposed in the first cutting station and fed through the first cutting nip A first cutting device for forming individual fiber bodies in the web arranged at a predetermined position relative to each other, and a rotatable first for transferring the fiber body from the first cutting station to the sealing station while maintaining the position relative to each other. And a vacuum transfer cylinder. The pad manufacturing apparatus is further provided with a sealing device disposed in the sealing station and defining a sealing nip, the at least first cover web being supplied to be laminated with the fiber body to form a laminated web and the laminated web to the sealing device. A first web supply device for passing the sealing nip to be sealed by a second cutting device disposed in a second cutting station and for cutting the sealed laminated web to form an interlabial pad.

In another embodiment, a system for folding interlabial pads includes a conveyor for transporting a series of said pads one by one to a folding station, and a folding for folding each pad disposed at said folding station and forwarded along its major axis. Device. The folding device comprises a hold-down member, which is in contact with a central section of the pad extending generally parallel with the main axis when each pad is transported forward, and disposed on opposite sides of the pressing member and And a pair of folding members that are brought into contact with the side sections of the pads on opposite sides of the main axis when the pads are conveyed forward and folded by the pressure members to their side sections facing each other.

In yet another embodiment, a pad wrapping apparatus for wrapping a pad includes a forming apparatus in which a web of flexible wrapping material is intended to be tensilely pulled thereon. The forming apparatus includes first and second folding members having curved folding edges contacted by respective opposite side margins of the web when the web is pulled past the folding edges, A web guide for guiding toward and an opening between the web guide and the fold edge, the center of the web being adapted to cross when the web is pulled past the forming apparatus. The pad wrapping apparatus further transfers a series of pads one by one and places the pads on the web as the web is pulled past the forming apparatus so that the pad moves with the web over the opening and past the folding edge of the forming apparatus. It includes a conveyor for. A device is used to apply a force to the pad to press the pad against the center of the web as the pad moves across the opening, which forces the web into a cup shape to move the pad past the first and second folding members. Enough to fold the side edges of the web by each folding edge and at the same time form a tube around the pad.

In another aspect, the present invention generally includes a method for manufacturing a folded interlabial pad, each having a fluid-absorbing body laminated with a first cover layer of fluid-permeable material. The method includes mixing fibers of different materials, at least one of which is absorbent, collecting mixed fibers at a collection station and transferring them to a forming station, and continuous mixed-fiber webs from the forming station to the mixed fibers. Forming a step. The method further includes manufacturing individual pads from the continuous mixed-fiber web and at least one first continuous cover web at a pad making station, folding each pad along its major axis at a folding station, and wrapping Wrapping each pad at the station.

In another aspect, a method of mixing a first and a second fiber comprises the steps of: conveying a first fiber feed to a first weighing station, conveying a second fiber feed to a second weighing station, a first amount of Metering and releasing the first fiber, and metering and releasing a second amount of the second fiber. The first and second amounts of fibers are transferred to the blend opener, open and mixed with the first rotatable roll in the blend opener. The blended fibers are entrained in an air stream to be transferred from the blend opener to the fine opener and further opened to mix with a second rotatable roll in the fine opener.

One method of forming a continuous mixed fiber web with a layer of blended fibers generally involves mixing the first and second fibers, collecting a feed of mixed fibers, and mixing the fibers from the feed. Supplying as an initial layer of fibers, crushing the initial layer into tufts and individual fibers at a fiberization station, and reforming the individual fibers as reformed layers of mixed fibers on a moving conveyor. Include.

In another aspect, a method for manufacturing a lamination pad having a fiber body, each of which is laminated with a first cover layer, is generally a first defined in part by a first rotating cutting roll having an outer surface with a vacuum opening formed therein. Feeding the fiber web through the first cutting nip at the cutting station, cutting the fiber webs fed through the first cutting nip to form individual fiber bodies in the web that are arranged in position relative to each other, and the interior A first cut to hold the fiber body in the predetermined relative position while rotating the first cut roll to transfer the fiber body to the first transfer nip between the rotary feed cylinder having a vacuum opening in the first cutting nip. Forming a vacuum in the vacuum opening in the roll. The laminated pad manufacturing method further includes forming a vacuum in the vacuum opening in the first transfer cylinder to transfer the first cutting roll from the first cutting roll to the first rotary transfer cylinder while maintaining the fiber body in the predetermined relative position, the fiber body Rotating the first conveying cylinder to convey the fiber body to the second conveying nip which is defined in part by a rotating first sealing roll having a vacuum opening therein while maintaining the predetermined relative position; Forming a vacuum in the vacuum opening in the first sealing roll for transfer to the first sealing roll in the second transfer nip while maintaining in the relative position. The method further includes rotating the seal roll to transfer the seal body to the seal nip defined in part by the first seal roll while maintaining the fiber body in the predetermined relative position, when the fiber body is transferred towards the seal nip. Laminating at least a first cover with the fiber body to form a laminated web, and sealing the laminated web in a sealing nip.

The method of folding the interlabial pad generally involves transferring a series of said pads one by one to the folding station in the direction along the major axis of each pad. The method further comprises contacting with the pressing means a central section of each pad extending generally parallel to the main axis when the pad is transported forward, and when the pad is transported forward to contact the pressure member. Contacting the side sections to opposite sides of the major axis to fold the side sections of the pad to a position facing each other.

In another embodiment, the pad wrapping method generally involves folding a web of flexible wrapping material, a folding edge that is brought into contact by each opposite side edge of the web when the web is towed past the folding edge. Pulling a web guide for guiding towards an edge, and past a forming apparatus having an opening between the web guide and the fold edge at which the center of the web is to cross when the web is pulled past the forming apparatus; . When the web is towed, a series of pads are placed one on the web so that the pads move with the web across the opening edge of the forming apparatus across the opening. When the pad moves across the opening, a force is applied to the pad to press the pad against the center of the web, which forces the web into a cup shape, passing the center of the web and the pad past the first and second folding members. It is sufficient to position it to move and at the same time fold the side edges of the web by each folding edge to form a tube around the pad.

Other features will be in part apparent and in part pointed out hereinafter.

1 and 2, the entirety of the interlabial pad 1 manufactured according to the method and apparatus of the present invention is shown. In the embodiment shown, the pad is generally oval in shape and has lateral protrusions 3. The pads can be manufactured in various sizes to suit a variety of users. For example, in one size, the pad has a total length of approximately 3.1 inches (7.9 cm) along the major axis A1 and a total width of approximately 2.7 inches (6.9 cm) along the minor axis A2. In another size, the pad has an overall length of approximately 4.3 inches (10.9 cm) along the major axis A1 and an overall width of approximately 2.7 inches (6.9 cm) along the minor axis A2. Those skilled in the art will appreciate that the pads may be manufactured in other sizes and shapes within the scope of the present invention.

In general, the pad comprises an absorbent layer or "core" 5 which is laminated between the first and second outer layers 7, 9. The absorbent layer is preferably a mixture of fibers, at least one of which is absorbent. By way of example, the fibers may comprise a mixture of cotton fibers that provide the requisite absorbency and rayon fibers that provide elasticity to the pad, wherein the cotton / rayon mixing ratio is desirable. Preferably it is 90/10 to about 50/50, More preferably, it is 80/20 to 55/45, Most preferably, it is about 60/40. Other fibers and mixing ratios may also be used. As will be appreciated by those skilled in the art, superabsorbent materials may be included. The thickness of the absorbent layer will also vary, but is preferably about 0.025 inches (0.635 mm) to about 1.5 inches (3.81 cm), more preferably about 0.05 inches (0.127 cm) to about 0.5 inches (1.27 cm), most preferred. Preferably in the range of approximately 0.08 inches (0.203 cm) (approximately 2 mm for low volume interlabial pads).

The first outer layer 7 (also referred to as the "cover" layer, or the bodyside layer as it faces the body when the pad is used) comprises a suitable polymer, such as polypropylene BCW, having a basis weight of 22 g / m 2. It is a fluid permeable layer. The second outer layer (also referred to as a "baffle" layer) may comprise a polyethylene film having a thickness of, for example, 0.75 mil (0.019 mm) to 1.0 mil (0.025 mm). Also contemplated are pads having other laminated structures including structures in which the shielding layer is fluid permeable. In any case, the circumference of the pad is sealed with the laminate 11.

3 and 4 show the pad in a folded state, in which the pad is folded along its long axis A1 to a position where the opposite side sections 1A, 1B of the pad face each other and the cover (body) Side) The layer 7 faces outward to contact the body when the pad is inserted for use. In one embodiment, the pad is held in this folded state by one or more adhesive spots 15 on the cover (shield) layer 9. As such folds, the lateral protrusions 3 on the pad are combined to form an area that the user can conveniently fold for insertion into an appropriate position in the body.

FIG. 5 shows the various stages in the overall process for commercially producing an absorbent article of laminated structure, including the interlabial pad 1 described above. This process involves a fiber mixing section 21 for mixing raw fibers (e.g., cotton and rayon fibers), and a fiber collecting and feeding section for collecting and feeding the feed of mixed fibers to the fiber forming section. 25, wherein the fiber forming section is formed of a relatively narrow continuous web that is used to make a fluid absorbent layer of the final product (e.g., interlabial pad 1). The process also has a pad making section 31 which combines the absorbent layer with the fluid permeable (cover) layer 7 and, when used, the shielding layer 9 to produce individual pads. This process also includes a folding section 33 having a device for folding the pads discharged from the pad making section 31, and the folded pads individually wrapped and optionally combined into a carton or other suitable bulk packaging. It has a pad packaging section 35 disposed thereon. Each stage of the process is described in detail below.

6 is a flow chart showing one embodiment of the fiber mixing section 21. In this particular embodiment, the fiber mixing section 21 is a first metering device 41 operable to meter and release the amount of the first fiber (eg, cotton), and a second fiber (eg, rayon). And a second metering device 43 operable to meter and release the amount of c. The metered and released amount is transferred to the blend opener 47 where the fibers are separated (“opened”) and And after being mixed, it is sent out of the blend opener by the air duct 49 of the pneumatic conveyor system, which carries an air separator 51 which separates the long fibers from the air stream and sends them to the fine opener 55. Short fibers (“fine fibers”) are sent to a microfiber collector, such as a bag filter 57. The micro opener 55 further opens and mixes the fibers to create an air duct 61. Through to the fiber collection section of the system (25) Song and. For each of these components of the mixing section in more detail described below.

For purposes of explanation, the device of the present invention is machine-direction (MD) extending in the direction of movement of the machine, lateral cross-direction (CD) extending across the machine direction, and z- Direction Z. As used herein, the machine direction MD is the direction in which a particular component or material is moved longitudinally along this position through a particular local position of the device. The transversal direction (CD) lies generally in the plane of the material being moved through the process and traverses relative to the local machine-direction (MD). The z-direction (Z) is aligned almost perpendicular to the machine-direction (MD) and the cross-direction (CD) and extends generally along the depth-direction, thickness dimension of the material.

The first metering device 41 is operable to deliver a continuous metered amount of the first fiber, such as cotton fiber. The particular unit shown in FIG. 7 is an M-6 “Syncro-Feeder” weigh pan feeder marketed by Fiber Controls Corporation, Gastonia, NC. The apparatus comprises a hopper 65 for holding a fiber stock feeder, and a conveyor 67 in the hopper for delivering fiber bundles from the feed to the meter housing 69, the meter housing being a hopper conveyor. A feed conveyor 71 for receiving the fibers from the 67 and transporting them to the inclined lift conveyor 73, wherein the inclined lift conveyor picks up the fibers from the feed conveyor 71 and at the exit of the unit a hopper Pins or spikes are provided that feed to the meter having 77. Oscillating combs 79 adjoining the upper end of the inclined conveyor 73 comb the fibers on the conveyor to separate (“open”) the large fiber bundles so that they do not enter the metering hopper 77. The fibers separated by the comb are transported to the apex of the inclined conveyor 73 and discharged onto one or more rotating doffer bars 81, which distribute the fibers more evenly into the metering hopper. . The excess fibers combed by the comb 79 fall back to the feed conveyor 71 for regeneration. The degree of fiber separation can be controlled by adjusting the speed of the inclined conveyor 73 and / or the spacing between the comb 79 and the inclined conveyor.

The metering hopper 77 has a suitable device 83 for measuring fiber metering in the hopper. Once a certain amount of fiber (e.g. 1120 grams of cotton fiber) with a given weight is received in the hopper, the door 85 above the hopper is closed and no longer enters the meter until the fiber is unloaded. Do not When the door is closed, the fibers discharged from the conveyor 73 are temporarily accumulated in the holding chamber 87 above the metering hopper 77. At the appropriate time, the metering hopper is opened to deliver the desired weight of fiber to the conveyor 91 (e.g., endless belt conveyor) located below, and then the door 85 allows more fibers to enter the metering hopper. Open the meter so that the cycle repeats.

The second metering device 43 is essentially the same as the first metering device 41 and is operated to release a continuous metered amount of the second fiber. Each of these amounts (eg, 480 grams of rayon fibers) is combined with a metered amount of the first fiber. This can be accomplished in a variety of ways, such as pouring a certain amount of second fiber directly onto the first fiber bundle when the first fiber bundle is transported under the meter of the second unit. The combined amount is then transferred to the blend opener by conveyor 91 (Figure 6).

Referring to Figure 8, the blend opener 47 may be of the type sold under the name Model B1X24 / 30 Opening Blender by Fiber Controls Corporation, Gastonia, NC. As shown, the machine comprises a housing 97, which has an inlet on one side wall for receiving the discharge end of the conveyor 91 from the meters 41, 43, on the upper wall of which air of the pneumatic conveyor system is shown. With an outlet connected to the duct 49, the pneumatic conveyor system generates a high velocity stream of air flow through the duct in a direction away from the outlet. Just above the discharge end of the conveyor 91 in the housing 97 is a feed roll 101 driven to match the speed of the conveyor 91. The feed roll 101 is formed with a series of axial ridges or flutes 103 on its outer surface, preferably a predetermined distance (e.g., from the upper reach of the conveyor belt 91). For example, the spring is pushed downward with respect to the stop (not shown) to a position 3 inches (7.62 cm) apart. The role of the feed roll 101 is to spread the fibers as a layer across the width of the conveyor 1 and press the fibers downward against the conveyor to forward at a relatively slow speed (eg 9 fpm (2.74 m / min)). To control the supply. At this point in the process, the fibers that make up the layer on the conveyor 91 form a relatively layer, such that the fibers first poured into the conveyor (eg, cotton) are at the bottom and the fibers poured next are It is at the top. The feed roll 101 and the conveyor 91 are preferably driven at the same speed by a common drive whose speed can be adjusted as needed.

A large cylindrical beater roll 105 having an axial dimension (eg, 24 inches (60.96 cm)) substantially coincident with the overall width of the conveyor 91 is provided within the housing 97 with the conveyor 91 and feed roll ( It is arranged to rotate upstream of 101. A plurality of pins or teeth 107 are mounted on the outer surface of the roll, each pin being screwed to the mounting block 109 fixed to the roll. Preferably, the pins 107 are arranged in parallel lines extending axially along the outer surface of the roll. (For example, a beater roll with a diameter of 24 inches (60.96 cm) can have 12 rows of pins mounted at equal angular spacing around it.) A cutoff blade 111 is disposed near the exit of the housing. This extends the full axial length of the roll immediately adjacent the tip of the pin (eg, the spacing can be approximately 0.02 inches (0.508 mm) to 0.05 inches (1.27 mm)).

The beater roll 105 is rotated at a relatively high speed (eg, approximately 750 rpm) by a suitable motor and drive train (not shown). The fibers fed towards the roll 105 by the conveyor 91 and the feed roll 101 are towed and combed at high speed by the pins 107 and are conveyed to the outlet of the housing 97, which exits. Is drawn into the air duct 49 and entrained in the air stream generated by the pneumatic conveyor system. The cutoff blades 111 help remove the fibers from the roll 105. The high speed traction and combing action for the fiber, combined with the pneumatic conveying of the fiber from the exit of the machine, further separates (“opens”) and mixes the fiber, as those skilled in the art will understand.

The air duct 49 transfers the fibers from the blend opener 47 to the air separator 51 by a high velocity air stream generated by a first transfer fan 115 (see FIG. 6) located downstream from the separator. In one embodiment, for example, the air moves at a speed in the range of 2500 to 4000 FPM (762 to 1219 m / min) and a flow rate of 1300 to 3500 CFM (36.81 to 99.11 m 3 / min). As shown in Figure 9, the air separator 51 in the preferred embodiment has an inlet section 123 having an inlet 125 for receiving airborne fibers from the blend opener 47, and an outlet section ( A housing 121 having a 127. The outlet section 127 has an upstream air outlet 131 for evacuating air from the separator and a downstream fiber outlet 133 for discharging the fibers from the separator to the fine opener 55.

The inlet and outlet sections 123 and 127 of the housing 121 have a path 137 through which the air stream entering the inlet pivots at a 90 ° corner at a corner, for example in the connection of the inlet and outlet sections. It is configured to flow along. As a result of this redirection, the majority of heavier fibers are moved outward by the centrifugal force and proceed to the fiber outlet 133. The rotary air lock 144 at the fiber outlet 133 allows the passage of the fiber while substantially preventing the flow of air through the outlet, thereby "separating" the fiber from the air. Like the revolving door, the air lock 144 includes a central hub 145 and a plurality of sealing arms 147 extending radially from the hub, the sealing arms having an outlet (< / RTI > It is wiped against the wall 151 forming 133. In a preferred embodiment, the air lock 144 is motor driven at a rate that can be varied to meet the fiber supply requirements of the system. As the air lock rotates, it sweeps the fibers laminated between the arms 147 through the outlet.

Since the flow of air through the fiber outlet 133 is almost blocked by the rotary air lock 144, the entirety of the air entering the pneumatic distributor 51 inevitably escapes through the air outlet 131. Catch large fibers near this air outlet 131 within housing 121 while allowing small fibers or “fine fibers” to move through the air outlet to air duct 157 leading to microfiber collector 57. Screen 155 is mounted, which may be any suitable configuration, such as a model AF-2 bag filter sold by Fiber Controls® Corporation of Gaston, NC. The mesh size of the screen 155 may vary depending on the required characteristics of the final product, but the openings in the screen preferably have a maximum dimension of approximately 0.125 inches (3.175 mm). The fibers collected on the screen are removed by the rotatable blade 161 mounted to the housing 121. The blade removes the fiber from the screen and transports it back to the air stream for transport to the fiber outlet 133.

A damper 165 in the air duct 157 connected to the microfiber collector 57 allows the air flow through the air outlet to the illustrated open position allowing air flow to the collector through the air outlet 131. It can move between closed positions that block. It should be noted in this regard that if a pneumatic conveyor system includes a plurality of air separators and associated components, there may be cases where a particular unit is not required, in which case damper 165 blocks the air flow through that particular separator. Can be closed. The first conveying fan 115 is mounted between the air separator 51 and the microfiber collector 57 in the air duct 157.

FIG. 10 shows one embodiment of a fine opener 55 sold by Model VFO 36 by Fiber Controls Corporation, Gastonia, NC. The fine opener has a housing having an inlet 173 connected to the fiber outlet 133 of the air separator 51 and an outlet 175 connected to the fiber collection and supply section 25 by an air duct 61. 171, which is equipped with a second conveying fan 179 to generate an air stream for conveying fibers from the fine opener 55 to the fiber collecting and feeding section 25. .

Immediately downstream from the inlet 173 in the housing 171 are mounted a number of fluted nip rolls (eg, three such rolls 181, 183, 185 are shown in FIG. 10) and these nips The roll rotates to transport the fibers entering the fine opener 55 along a path between a pair of tightly spaced feed rolls 187 which also have a fluted surface. (The flutes on the nip rolls 181, 183, 185 are typically relatively narrow and resemble blades or pins that extend by the full length of each roll at spaced circumferential intervals around the rolls, and flutes on the feed roll 187. The feed roll 187 preferably rotates the fiber in the housing 171 at high speeds, for example 1000 rpm, for example. To supply. Applied card clothing 193 (e.g., a tooth or a hook) is mounted on the cloth roll 191 along a continuous spiral path from one end of the cylinder to the other end, as those skilled in the art will understand. will be. The nip rolls and feed rolls are preferably driven by a common DC motor 197 whose output is adjustable to vary the speed of these rolls as needed. The coating roll 191 is preferably driven by an AC motor (not shown) to rotate the roll at a constant speed.

As the sheath roll 191 rotates at high speed past the feed roll 187, the sheath on the roll acts to further open the fiber and transport it to the outlet 175 of the machine, with the fiber being pulled upward through the outlet. . The cutoff blade 201 mounted near the outlet has an edge disposed close to and adjacent to the roll 191 to substantially prevent the fiber from being transported past the outlet 175 by the coating roll. A tip of a similar blade 205 is mounted near the top feed roll 187 to prevent the build up of fibers on the feed roll. Air enters the housing 171 through the air inlet 207.

In the housing 171 of the fine opener 55 is mounted a fiber-level sensor (eg, photocell) (not shown) for adjusting the level of fiber sent to the inlet 173. If the fiber is returned to a level considered excessive, the sensor will no longer provide upstream metering devices 41, 43 and blend opener 47 until the fiber level drops below a predetermined level (e.g., the level of the sensor). It may be operable to signal to stop fiber delivery, and then the upstream equipment is signaled to resume operation. Other sensing devices that work in other ways may be used.

11 and 12 show the apparatus in the fiber collection and feed section 25 of the system downstream of the fine opener 55. This apparatus, in one embodiment, includes a supply chute 221. The feed chute collects (accumulates) the mixed fiber feed and feeds it to the fiber forming section 27 as an initial layer or mat of mixed fibers. More specifically, the feed chute 221 is an inlet 225 connected to an air duct 61 for receiving fibers from the fine opener 55, and an outlet through which a continuous feed of mixed fibers is discharged into the forming section. And a housing 223 having 227. The particular supply chute 221 disclosed in this embodiment is a model FCF-40 chute feeder sold by Platt-Saco-Lowell, formerly Greenville, SC.

The housing has an upper section 229 with an upper chute 231 for holding the fiber feed discharged through the inlet 225, and a lower section 233. One wall 237 of the upper chute 231 is perforated to allow escape air from the chute (eg, the wall may be a screen of fine mesh). The fiber level in the upper chute 231 may provide an upstream device (e.g., a shutoff signal) indicating that the upper chute 231 is full when the air pressure in the upper housing section 229 exceeds a predetermined pressure. To the metering device 41, 43, blend opener 47, and fine opener 55, and when the pressure drops below a predetermined pressure, an upstream operation signal indicating that the fiber feed in the upper chute has dropped to a level requiring replenishment. Controlled by suitable means such as pressure switch 241 near the inlet, operable to send to the equipment.

Just below the upper chute 231 in the lower section 233 of the housing is a feed roll 245 rotatably mounted to feed fiber from the upper chute 231 to the beater roll 247. The fibers pass through the feed roll 245 through a gap 251 (FIG. 12) defined by a guide surface 255 spaced from the feed roll 245 by a suitable distance (eg, approximately 0.25 inch (6.35 mm)). Supplied. The feed roll 245 preferably has a needle (not shown) similar to the covering cylinder of the fine opener 55, and the beater roll 247 has a rather small (e.g., twelve rows of pins or teeth). Having a diameter of 10.5 inches (26.67 cm), but have a structure similar to the beater roll 105 in the blend opener 47. The feed roll 245 is preferably rotated by a variable speed motor (not shown) to feed the fibers to the beater roll 247 at a predetermined speed. The beater roll 247 is preferably rotated at an appropriate speed (e.g., 1800 rpm) by a constant speed motor to feed the blended fibers to the lower section 233 of the feed chute and to perform further opening steps on the fibers. . The fibers on the beater roll 247 are directed by the adjacent guide wall 261 in the housing to the top end of the fiber accumulation chute 263 in the lower section 233 of the housing 223.

Referring to Fig. 11, the lower accumulation chute 263 is defined in a preferred embodiment by a vertical wall, one of which comprises a shaker plate 267, which shaker arm assembly is near its lower end. It is pivoted at its upper end to swing back and forth by 271. The shaker arm assembly 271 includes one or more shaker arms 273, each of these shaker arms having an inner end connected to the wheel at an off-center position and a shaker plate 267 (clevis 277). And the shaker arm and shaker plate swing back and forth by rotation of the wheel. This movement prevents the bridging of the fibers in the lower chute 263 and promotes uniform feeding and packing of the fibers within the chute, for example, at a uniform density or "base weight" (typically g / m 2). Feed of mixed fibers, such as a column of measured). The length of the shaker arm 273 is adjustable by a turnbuckle, thus changing the amplitude of the rocking motion as needed. Shaker arm wheel 275 (or multiple wheels) is preferably driven at a predetermined speed by a variable speed DC motor (not shown). Other means may be used instead of the shaker plate and shaker arm assembly 271 to facilitate the flow and packing of fibers in the lower chute 263.

The fiber level in the lower accumulation chute 263 is controlled by a pair of upper and lower sensors, for example, suitable means such as upper and lower photocells, shown at 285 and 287 in FIG. 11, respectively. The upper photo cell 285 is provided with an upstream device (e.g., the metering devices 41 and 43) to block the signal indicating that the lower chute is full when the height of the fiber column in the lower chute 263 exceeds a predetermined height. Blend opener 47 and fine opener 55). The lower photo cell 287 can be operated to send an upstream equipment operating signal to indicate that additional fiber is needed when the column height drops below a predetermined level. The upper and lower sensors 285 and 287 are preferably closely spaced to keep the height of the fiber column constant so that the density of the fibers emitted from the chute is substantially uniform.

The fibers in the lower chute 263 are fed through the outlet 227 by feed means comprising a pair of compression rolls 291, which in one embodiment form a compression nip 293 near the outlet of the housing. . These compression rolls 291 preferably serve to compress the fibers into a continuous mat or layer 295 of mixed fibers released through the outlet 227 and to send them to the fiber forming section 27 of the system.

13-15 illustrate one embodiment of the forming section 27 of the system of the present invention. In this section, the layer 295 of fiber discharged from the outlet 227 of the feed chute 221 is crushed, so that the width of the absorbent layer of the final product (e.g., layer 5 of the pad 1) is reduced. It is reformed as a preferably (but not necessarily) narrow layer having a generally consistent width. In general, the fiber forming section 27 of this particular embodiment includes a conveying device 301 for feeding a layer of fibers from the outlet 227 of the feed chute to the fiberizing station 303 at the downstream end of the conveying device. . In a preferred embodiment, the conveying device is a slide (also referred to as 301) in which the layer falls down.

The fiberization station 303 is provided with an apparatus 311 for breaking up the entering layer 295 into individual fibers, which is a process that may be referred to as "fibrillation". As shown, this fiberizing apparatus 311 comprises a feeding mechanism having a feed roll 315 spaced from the guide surface 317 (FIG. 14) to form a gap 319, through which the fiber layer 295 ) Is fed to a fiberizing apparatus comprising in one embodiment a roll 321 having a tooth, for example a lickerin roll, mounted immediately adjacent to the gap. Alternatively, a rotary hammer mill or other device may be used.

The feed roll 315 is carried by a pair of levers 325 (only one is shown in FIG. 14), each of which has a pivot connection 327 with the machine frame to adjust the size of the gap 319. . The gap is thinner (eg, approximately 2.5 inches (6.35 cm) than the thickness of the entry layer 295 so that the layer of fibers is compressed and transported forward at a controlled rate (eg, 6 fpm (1.83 m / min)). 0.012 inch (0.3048 mm)). The supply roll 315 is preferably driven by the variable speed DC motor 329 (Fig. 13). The fiberizing roll 321 is preferably rotated in a direction opposite to the direction of rotation of the feed roll 315, and the tissue layer 295 on the roll 321 is crushed or " fibrated into a tuft and individual fibers. "It works. The fiberizing rolls are preferably driven by the AC motor 333 at a constant relatively high speed (eg, 1800 to 2400 rpm).

The fiber forming section 27 is also disposed under the fiberizing roll 321 and extends in the foraminous forming surface 337 in a direction generally transverse to (eg, at right angles to) the feeding direction to the fiberizing roll. Conveyor 335, and a fiber-orienting device 341 for directing fibers from the fiberizing roll to the forming surface 337, on which the fibers are referred to as " reform " conveyors. Reconstructed as a "reformed" layer 343 (FIG. 14) on 335. In one embodiment, the forming surface 337 of the reforming conveyor 335 comprises an endless belt made of wire mesh or screen, and the opening is sized appropriately for formation (eg, 11% open area). The forming surface 337 is preferably substantially narrower than the width of the layer 295 fed to the fiberizing roll 321 (eg 3 inches (7.62 cm) to 40 inches (101.6 cm)), one embodiment. In the example it extends generally parallel to the axis of rotation of the fiberizing roll.

It should be appreciated that fibrous instruments other than rolls with teeth (eg, liquorine roll 321) may be used within the scope of the present invention. Any instrument (eg, a rotary hammer mill) can be used as long as the layer 295 can be broken into individual fibers to be reformed on a reform conveyor 337 in an almost irregular orientation.

14 and 15, the fiber-orienting device 341 includes, in a preferred embodiment, an air chamber 347 disposed between the fiberizing roll 321 and the reform conveyor 335. The air chamber 347 may have an orientation other than vertical within the scope of the present invention, but the upper inlet disposed near the fiberizing roll 321 and the lower disposed directly above the forming surface 337 of the conveyor 335. Has an exit.

As seen in Figure 15, where the reform conveyor 335 carries the fibers from right to left, the upper end of the air chamber is preferably at least as wide as the layer 295 sent out from the feed chute 221 and the axial length of the fiberizing roll 321. Have a length that generally matches. Referring to Figure 14, the air chamber 347 is at least partially defined by a door pivoted at its upper end 353 so as to swing up and down between the open and closed positions in one embodiment (left). It has a wall 351, a back wall 355, and an opposing side wall 357 (FIG. 15). The air chamber 347 draws a width (ie, the distance between the front wall 351 and the rear wall 355 of the chamber) that generally corresponds to the width of the reformed layer 343 of fibers formed in the reform conveyor 335. At the bottom. Forming surface 337 of conveyor 335 is disposed above elongate air manifold 361 in communication with a vacuum fan (not shown) by air duct 363. In this arrangement, when the fan is operated, an air stream for "air laying" the fiber layer to the forming surface occurs downwardly through the air chamber 347 and the forming surface 337. Air is provided to the air chamber 347 via an airway 367 (FIG. 14) near the connection of the fiberizing roll 321 and the upper inlet end of the air chamber.

The ventilator has a throat 371 that can be sized to regulate the air flow into the air chamber, and the size can be adjusted, such as a movable saber bar 373 or other suitable device. Is made by To prevent air from entering the air chamber 347, a seal is provided that includes a side of the door, a sealing strip 375 along the upper edge of the door, and a strip along the lower edge of the door and the rear wall ( Figure 14). The vacuum fan generates a relatively high velocity air stream through the air chamber 347 sufficient to direct the fibers from the fiberizing roll 321 onto the reform conveyor 335 to form a layer of mixed fibers of appropriate thickness and density. It should be sized to

The reformed layer 343 may be formed on a conveyor other than the endless belt. For example, the reformed layer can be laminated or "air laid" in a rotatable vacuum drum of a type known in the art to produce a fibrous web formed from air.

Fracture or decomposition of the fiber layer 295 by the fiberizing roll 321 and lamination of the fiber as the reformed layer 343 on the reforming conveyor tends to make the orientation of the fiber irregular, resulting in a final product. The tensile strength of is good in all directions and more uniformly infiltrates and distributes body fluids in all directions from the impact location for the fibers. In addition, reforming the layer 295 at an angle (eg, 90 °) transverse to the machine direction MD of the feed to the fiberizing roll 321 tends to average any cross-sectional area change within the layer. have.

As best shown in Figure 15, the reforming conveyor 335 is designed to drive the conveyor at a rate substantially faster than the rate at which the initial layer 295 of fibers is fed from the feed chute 221 to the fiberizing roll 321. It is driven by the drive roll 381 which is driven by a suitable motor. Preferably, the width of the initial layer 295 sent out from the feed chute is at least five times greater than the width of the reformed layer 343 on the reform conveyor 335, wherein the reform conveyor is at least greater than the rate at which the initial layer is fed into the fiberizing roll. It is desirable to move at 10 times faster speed.

For example, the initial layer may have a width of approximately 40 inches (101.6 cm) and a thickness of approximately 2.5 to 3.0 inches (6.35 to 7.62 cm), and the rate at which the initial layer is fed to the fiberizing roll is 5 to 8 fpm (1.52). To 2.44 m / min). The reformed layer, on the other hand, may have a width of approximately 3 inches (7.62 cm) and a height of approximately 0.5 inches (1.27 cm), and the reform conveyor 335 may move at a speed of 370 fpm (112.78 m / min). . The speed of the reform conveyor is preferably adjustable. The fiber duct is removed from the reforming conveyor by a cleaner 385 mounted upstream of the belt drive roll. In one embodiment, the cleaner includes an air jet operable to blow fibers away from the conveyor, and a vacuum pickup (not shown) facing the air jet. Other cleaning mechanisms may be used. The endless belt of conveyor 335 is tensioned by conventional tensioning device 389.

The door 351 in front of the air chamber 347 may be opened to access the reform conveyor 537 and associated equipment. However, during normal operation, the door 351 is held in its closed position by a pair of locking pins 393. An additional security system 395 (FIG. 14) may be provided to lock the door closed.

After the fibers are reformed on the reform layer 335 as a narrow layer, the reformed layer 343 is compressed to a final thickness. Compression is preferably done in two stages. In the first step, the reformed layer is lightly compressed by a compression conveyor 401 disposed above the reform conveyor 335 downstream of the air chamber 347 (FIGS. 15-17). The compression conveyor 401 is preferably an endless belt having a lower reach spaced from the forming surface 337 of the reforming conveyor 335 by a distance sufficient to lightly compress the entry layer 343 of the fibers. The vertical position of the compression conveyor 401 is preferably able to be adjusted to vary the size of the gap between the two belts, and thus the amount of compressive force exerted on the layer, as necessary.

In a second step, layer 343 is compressed more severely by de-bulking module 405 (FIG. 17). In one embodiment, the module 405 includes a pair of compression rolls having a hardened surface, such that the lower compression roll 407 is mounted in a fixed position and the upper roll 409 is mounted on the upper roll. The power cylinder 411 can be moved perpendicularly to the lower roll. The power cylinder applies downward force (e.g., 2400 lbs (1088.6 kg)) to the bearing block 415 at the end of the upper roll to keep the block pressed against a fixed stop (not shown), the stop The blowing unit maintains a gap of a predetermined size between the pressure rolls unless the compressive force exerted on the layer 343 by the rolls 407 and 409 exceeds a predetermined value (in this case the upper roll 409 will yield upwards). do. The gap size in the nip of rolls 407 and 409 can be adjusted by changing the position of the fixed stop. The compressive force exerted by the pressure rolls causes the layer 343 to have a final thickness that is approximately equal to the thickness of the absorbent layer of the final product (e.g., layer 5 of pad 1) (e.g. 0.08 for interlabial pads). Sufficient to compress to inches (2.03 mm) is preferred. After so compressed, the layer 343 is preferably conveyed by the one or more conveyors 421 to the pad making section 31 as a continuous integral web 417 (FIG. 17) of mixed fibers.

Referring to Figures 16-19, the pad fabrication section 31 is generally made of a material on which the webs 7W, 9W of the material corresponding to the cover layer and the shielding layers 7, 9 of the final pad 1 are wound. A first and second unwind rolls 425 and 427, and a first cutting station 431, wherein the web 417 of mixed fibers is cut at the first cutting station to separate the absorbent body into the web. (For example, the core 5 for the pad 1) is formed. The pad manufacturing section 31 also has a web sealing station 435 and a second cutting station 441 in which the cover and shielding webs 7W, 9W are sealed around the body 5. Applied to opposite sides of the body 5 to form a laminated web 437 (FIG. 19), in which the laminated web 437 is cut around the pad before the pad is transferred to the folding station 31 do. Each of these components is described in more detail below.

A conveyor (e.g., an endless belt conveyor 447 comprising a belt tensioning device 449) receives the mixed-fiber web 417 at the entry end of the pad making section (which is the left end when viewed in Figure 18). And transfers it to the first cutting station 431. The station is provided with a cutting device, which in one embodiment comprises opposing cutting rolls 451, 453 forming the first cutting nip CN1. One of these rolls 451 is a knife (die) roll and the other roll 453 is an anvil roll. In this embodiment, the knife roll 451 is mounted at a fixed vertical position under the anvil roll 453, but this orientation may be reversed. The knife roll 451 has a series of cutting dies (blades) 457 (FIG. 20) mounted on the rolls in a pattern that matches the pattern of the absorbent body (e.g. core 5) to be cut in the web. do. The anvil roll 453 has a hardened and polished metal surface, preferably in the first cutting nip CN1 such that the cutting blade 457 can cut the mixed-fiber web 417 almost completely. The gap between the rolls is placed small enough (eg, 0.0005 inches (0.0127 mm)).

The anvil roll 453 is preferably movable vertically relative to the knife roll 451 in the manner described above with respect to the upper pressure roll 409, for which purpose a power cylinder 461 is provided. The cylinder exerts a downward force on the bearing block of the anvil roll 453 to keep the block pressed against a fixed stop (not shown), thereby being applied to the web 417 by the rolls 451 and 453. The losing force maintains the size of the gap (if any) in the first cutting nip CN1 unless the compressive force exceeds a predetermined value (in this case the upper roll will yield upwards). The size of the gap can be adjusted by changing the position of the fixed stop, which will be understood by those skilled in the art.

After the web 417 is cut to form an absorbent body (eg core 5), it is desirable to maintain the body in the correct position when the body is moved through the pad making section 31, thus The various components of the final pad (eg pad 1) are almost exactly matched. To this end, the knife roll 451 is a vacuum roll comprising a cylindrical body 465 (see FIGS. 20-22) in which a vacuum passage is formed, which in one embodiment is from the end of the body along the length of the body. An extending axial passage 467 and a radial passage 469 extending radially outward from the axial passage 467 to form a vacuum opening 471 (FIG. 20) in the outer surface of the body. . Opposite ends of the body 465 are equipped with vacuum boxes 475, each box being open near each end face of the body. The vacuum box 475 is in communication with the vacuum system by an air duct 479, which vacuum system generates at least one vacuum fan to generate negative pressure in the vacuum box to draw air through the passages 467 and 469 to the body. (Not shown). Seals 483 around the openings in each vacuum box 475 are disposed close to each end face of the rotating cylinder 465 to seal air leakage from the box.

In the embodiment shown in Figures 18 and 20, the vacuum box 475 is a knife from the 12 o'clock position to the 3 o'clock position near the first cutting nip CN1 for transferring the absorbent body to the first transfer cylinder 485. Extending over an arc segment of approximately 90 ° along the top of the roll 451, the conveying takes place in a first conveying nip TN1 defined by the knife roll 451 and the conveying cylinder 485. The vacuum opening 471 on the outer surface of the knife roll 451 is used when the absorbent body cut from the web is vacuum-held and the knife roll rotates clockwise from the cutting nip CN1 to the first feed nip TN1. Arranged and arranged to remain in the correct position on the knife roll, the absorbent body in the transfer nip is conveyed to a first transfer cylinder 485 that rotates in the same direction as described below. During or after the transfer of the absorbent body, the scrap material 491 (e.g., a trim from the web 417 around the absorbent body) is cut by a knife roll by a vacuum duct 493 (FIG. 22). Is removed from. The duct 493 has an inlet near the knife roll 451 and draws scrap material 491 into the duct and into the inlet section of the feed chute 221 for regeneration or to an appropriate waste collector for disposal. In order to communicate with the vacuum system.

20 and 21, the body 465 of the knife roll 451 is a sleeve made of a number of arcuate segments (eg, three such segments 499A-499C are shown in FIG. 20). It may be a multipiece structure comprising a shaft 497 surrounded by 499, wherein the arcuate segment extends through the bore 503 in the sleeve 499 and is screwed into the shaft 497. 501 (FIG. 21) is fixed to the shaft. In one embodiment, each segment 499A to 499C is responsible for two cutting dies or blades 457, each of which is contoured to match the shape of the absorbent body 5 to be cut from the web. Has An insert 507 (FIG. 23) of compressible but elastic material is secured to the outer surface of the body 465 of the knife roll 451 inside the perimeter of the blade 457 with a suitable adhesive. The insert 507 is crosslinked, for example, having a tensile strength of 44 to 55 psi (3.03 to 3.79 bar), and a compression that causes the material to deflect 25% at a pressure of 12.7 to 15.5 psi (0.88 to 1.07 bar). Adhesive-backed body formed from a polyethylene foam. Such foams are commercially available under the trade name "Volara" from McMaster-Carr Supply Company, Chicago, Illinois. In its relaxed (uncompressed) state, as shown in FIG. 23, the insert 507 preferably projects from the surface of the knife roll 451 by a distance slightly greater than the height of the cutting blade 457. For example, for a cutting blade 457 having an overall height of 0.19 inches (4.83 mm), the insert 507 may protrude out by a distance of 0.125 inches (3.175 mm). The insert 507 is porous (due to the porous nature of the insert material or the holes 509 made in the insert) for transferring vacuum through the insert from the vacuum opening 471 at the surface of the knife roll 451. to be. When the absorbent material web 417 passes through the cutting nip CN1, the insert 507 is compressed to allow cutting of the material by the blade 457. After the web passes through the cutting nip, the tendency to expand into its relaxed state of the insert 507 exerts a small outward pushing force on the absorbent body 5 cut by the cutting blade 457. This outward force helps to cleanly separate the absorbent body 5 from the web 417 and to transfer the absorbent body to the first transfer cylinder 485 in the first transfer nip TN1.

As shown in Figs. 24 and 25, the first transfer cylinder 485 has a cylindrical outer surface formed with a pattern of vacuum holes 519 which substantially matches the shape of the absorbent body 5 transferred from the knife roll 451. A hollow body in the form of a drum 515. The vacuum box 521, which is mounted at a fixed position inside the drum 515, has an arcuate surface 525 that defines a vacuum opening 527 located immediately adjacent to the inner wall 529 of the drum. The vacuum box 519 is opened by one or more air ducts 531 so that underpressure is generated in the vacuum box to draw air through the vacuum holes 519 on the outer surface of the drum as the drum rotates past the box. Communicate with the vacuum system. Seal 533 around opening 527 in the vacuum box is wiped against inner wall 529 of rotating drum 515 to seal leakage of air. In the embodiment shown in Fig. 18, the vacuum box is moved from approximately 9 o'clock position to approximately 3 o'clock position near the first transfer nip TN1 to transfer the absorbent body 5 to the web sealing station 435 as will be described later. Along the lower half of the drum it extends over an arcuate segment of at least about 180 ° (eg, about 190 °). The vacuum hole 519 in the first transfer cylinder 485 is vacuum-absorbed by the absorbent body transferred to the first transfer cylinder 485 in the first transfer nip TN1, and the transfer cylinder is removed from the nip TN1. It is arranged and arranged to remain in the correct position on the transfer cylinder when rotating counterclockwise to the approximately 3 o'clock position. An exemplary pattern of vacuum holes 519 is shown in FIG.

In the embodiment shown in Fig. 18, the web sealing station 435 has a sealing device, which in one embodiment has a pair of opposing sealing rolls 541, 543 defining a sealing nip SN. One such roll 541 is shown as a lower seal roll and the other roll as an upper roll. The upper seal roll 543 has a smooth, uninterrupted cylindrical surface and is mounted to the first cutting section 431 in the same manner as the anvil roll 453, for which purpose a power cylinder 547 is provided. The lower seal roll 541 is mounted to rotate in a fixed vertical position and defines a second transfer nip TN2 along with the first transfer cylinder 485. The lower sealing roll 541 has a smooth cylindrical outer surface 551 formed with a recess or pocket 553 pattern having a size and shape such that the body receives the absorbent body 5 conveyed from the first transfer cylinder 485. It has a structure similar to the knife roll 451 except that it has a. Each pocket 553 has a slightly larger contour than the contour of the absorbent body 5. The pocket 553 has a depth slightly larger (ie in the Z direction) than the depth of the absorbent body 5 so that the absorbent body is not compressed in the sealing nip SN. Alternatively, the depth of the pocket 553 can be made smaller than the thickness of the absorbent body 5 to slightly compress the absorbent body in the sealing nip if necessary.

The depth of the pocket 553 can be controlled by placing one or more perforated inserts of predetermined thickness in the pocket. Like the knife roll 451 at the first cutting station 431, the lower sealing roll 541 also has a series of axial and radial directions therein to create a vacuum opening 561 in the outer surface 551 of the roll. It is formed (eg, machined) to have vacuum passages 557 and 559. Also like the knife roll 451, a vacuum box 565 is disposed near the opposite end of the lower sealing roll 541, which vacuum air to generate a vacuum in the vacuum opening 561 on the roll 541. The duct 567 is connected to the vacuum system. FIG. 26 shows a pair of exemplary pockets 553 formed on the outer surface 551 of the lower seal roll 541.

In the embodiment shown in Fig. 18, the vacuum box 565 at the end of the lower sealing roll 541, together with the lower sealing roll 541, absorbs the absorbent body 5 and the accompanying webs 7W, 9W. Approximately 180 ° along the upper half of the roll from the 9 o'clock position to the approximately 3 o'clock position near the second transfer nip TN2 to transfer to the downstream second transfer cylinder 571 defining the third transfer nip TN3. It extends over an ideal (eg approximately 190 °) arcuate segment. In an alternative embodiment, the vacuum box 565 at the end of the lower seal roll 541 is located at approximately 9 o'clock position near the second transfer nip TN2 for transporting the absorbent body 5 and the accompanying web. At approximately 12 o'clock it extends over the arcuate segment along the top of the roll. As described in more detail below, the two sealing rolls 541 and 543 apply the cover and shielding webs 7W and 9W from the unwinding rolls 425 and 427 to the absorbent body 5 to the laminated web 437. ) And then seal to deliver the laminated web to the third transfer nip TN3.

An apparatus for supplying the cover web 7W to be laminated with the absorbent body is shown in FIG. The device is a cover web 7W material, corresponding to the cover layer 7 of the final pad (eg pad 1), mounted to a shaft 575 driven by a variable speed motor (not shown). Unwinding feed roll 425. The speed of the motor is controlled such that the speed at which the web 7W is fed from the roll 425 matches approximately the speed at which the mixed fiber web 417 is fed to the pad making section 31. One aspect of this feed control speeds the motor to, for example, detect a change in web tension due to a decrease in roll diameter as the web is fed from the roll, and also maintain a nearly uniform tension corresponding to the desired speed in the web. Included downstream of unroll roll 425 is a sensing device 581 for signaling to speed up or slow down. In one embodiment, the sensing device 581 includes a dancer bar 583 pivoted on a frame of the machine, a dancer roll 585 rotatable in contact with the web 7W on the bar, and web tension. A potentiometer (not shown) for sensing the movement of the bar as a result of the change. Other sensing devices can be used. The cover web W is directed to the lower sealing roll 541 by a series of idler rolls 589, where it is pulled through the second transfer nip TN2.

As the web is pulled through the nip, the absorbent body 5 is transferred from the first transfer cylinder 485 to the lower seal roll 541, which deposits the absorbent body on the web to form a laminate. So that it rests on the cover web 7W. The cover web 7W is made of air and fluid permeable material, so that the web and the absorbent body are applied by a vacuum opening 561 in the seal roll 541 to maintain it in the correct position on the lower seal roll (see FIG. 19). You lose a vacuum. In addition, a pocket 553 at the outer surface 551 of the lower seal roll 541 is arranged to receive the absorbent body conveyed from the first transfer cylinder 485, so that the cover web and the absorbent body are lower seal rolls. It is held in the pocket by the vacuum of and kept in this laminated state so as to be transferred to the sealing nip SN.

An apparatus for supplying the shielding web 9W to be laminated with the cover web 7W and the absorbent body 5 is also shown in FIG. The device is made of a material of shielding web 9W, corresponding to the shielding layer 9 of the final pad (assuming a shielding layer is included), mounted to a shaft 591 driven by a variable speed motor (not shown). Two unwinding feed rolls 427. The operation and speed of the motor is similar to that of the first unwind roll 425 described above and is not described again. A web tension sensing device 595 similar to the device 581 is provided downstream of the second unwind roll 427. The series of idler rolls 599 directs the shielding web 9W past the applicator 601, which in one embodiment is directed to the face of the web 9W to be applied to the absorbent body 5. As shown in Fig. 1, an appropriate adhesive (for example, a hot-melt adhesive) is applied at a position generally coincident with the peripheral seal 11 of the final pad. Other types of applicators, adhesives, and / or sealing methods may be suitable. An additional idler roll downstream of the applicator 601 directs the shielding web 9W to a sealing nip SN defined by the sealing rolls 541, 543, where the shielding web is the upper of each absorbent body 5. Applied on the side opposite to the cover web 7W, the adhesive on the shielding web contacts the lower sealing roll.

As the stack of webs 7W and 9W and the absorbent body 5 pass through the sealing nip SN (FIG. 19), pressure is applied by the sealing rolls 541 and 543, which results in a shielding web 9W. The adhesive on) contacts the opposing surfaces of the cover web 7W to seal the cover web and the shielding web together around each absorbent body 5. If a hot melt adhesive system is used, the distance between the applicator 601 and the sealing nip SN must be such that the adhesive is sufficiently heated in the sealing nip to form a suitable seal given the rate at which the shielding web 9W is fed forward. do. Alternatively, one or both of the seal rolls 541, 543 may be heated (ultrasound or otherwise) to form heat seals around the absorbent body.

In the preferred embodiment of Figures 19, 26 and 27, the vacuum opening 561 in the lower seal roll 541 vacuum grips the sealed laminate web 537. As the seal roll rotates, the seal roll exerts a traction on the web to transfer the web clockwise from the sealing nip SN to the approximately 3 o'clock position, where the web is located in the second feed nip TN3. It is conveyed to the transfer cylinder 571. In one embodiment, the structure of the second transfer cylinder 571 is essentially the same as the structure of the first transfer cylinder 485. In the embodiment shown in Fig. 18, the vacuum box 603 inside the second transfer cylinder 571 is used to transfer the sealed transfer web 537 to the second cutting station 441, the third transfer nip TN3. ) Extends over an arcuate segment of at least about 180 ° (eg, about 190 °) along the lower half of the cylinder from an approximately 9 o'clock position to an approximately 3 o'clock position. A vacuum opening (not shown) in the second transfer cylinder 571 is arranged and arranged such that the web is vacuum gripped and towed while the web is held in the correct position as the cylinder rotates counterclockwise. In an alternative embodiment, the second transfer cylinder 571 does not have a vacuum box or vacuum opening, and the web is transferred to the second transfer cylinder 571 without using the vacuum opening.

The second cutting station 441 has a second cutting device, which, in one embodiment, includes a second pair of opposing cutting rolls 607, 609 defining a second cutting nip CN2. And in the second cutting nip, the sealed laminate web 537 is cut to form individual pads (eg, pad 1). In this particular embodiment, the cutting roll includes a lower knife roll 607 and an upper anvil roll 609 similar to the two cutting rolls 451 and 453 at the first cutting station 431. The knife roll 607 at the 2nd cutting station has the 5th between the knife roll 607 and the cylinder 615 by the vacuum box 611 at the end of the roll 607, as shown in FIG. Approximately three o'clock from the position of approximately nine o'clock in the vicinity of the fourth conveying nip TN4 between the knife roll 607 and the second conveying cylinder 571 for conveying to the third conveying cylinder 615 in the conveying nip TN5. It is preferably a vacuum roll having a structure and operation similar to the knife roll 451 at the first cutting station, except that it extends over an arcuate segment of at least approximately 180 ° along the top of the knife roll in position. Alternatively, the vacuum box 611 at the end of the roll 607 is positioned approximately 3 o'clock from the approximately 12 o'clock position near the second cutting nip CN2 for transferring the cutting web to the third transfer cylinder 615. It extends over the arcuate segment along the top of the furnace knife roll.

As shown in Fig. 28, the vacuum opening 617 on the outer surface of the knife roll 607 at the second cutting station pulls the web from the fourth transfer nip TN4 to the second cutting nip CN2. And the lamination web 537 is vacuum-held and rotated clockwise to transport so that it is arranged and arranged to remain in the correct position on the knife roll. Knife roll 607 has a cutter blade (or die) 621 shown in FIG. 28 spaced at repeated intervals, for example, around the roll. The cutting blade 621 has a cover and shielding webs 7W, 9W cut around the absorbent body 5 as the laminated web 537 moves through the second cutting nip CN2 so that individual pads (eg, It is configured to form the interlabial pad 1. Since the cover and the shielding web are typically of polymeric material, the cutting blade 621 has an interference fit with the anvil roll 609 at the second cutting nip CN2 such that the laminated web is surely fully penetrated (ie, gaps). No gaps). (If other web material is used, the spacing at CN2 may be changed.) The cutting action is sometimes referred to as the cut and is surrounded by the remaining scrap portion 625 of the web, which typically has a ladder appearance. (1) is formed. As shown in FIG. 28, the rail 627 of the "ladder" corresponds to the unused extreme side edge edge of the web 537, and the rungs 629 of the "ladder" are sealed regions of the laminated web. Corresponds to the unused part of. If necessary or required, an elastic insert similar to the insert 507 described above may be disposed within the cutting blade 621. After cutting in the nip CN2, the pad 1 and the cut 629 are transported from the second cutting nip CN2 by the knife roll 607 for transfer to the third transfer cylinder 615. Vacuumed to nip TN5.

The third conveying cylinder 615 has a vacuum conveyor in which the roll conveys the pads to the folded section of the machine from the approximately 9 o'clock position in the fifth conveying nip TN5 by the vacuum box 635 (FIG. 29) therein. In essence the first and second transfer cylinders (except that they extend only along an arcuate segment of approximately 90 ° at the bottom of the roll to an approximately 6 o'clock position forming a sixth transfer nip TN6 together with 641). 485, 571). A vacuum opening (not shown) in the outer cylindrical surface of the third transfer cylinder 615 vacuum-holds the pad 1 transferred from the knife roll 607, and the pad is transferred counterclockwise by the transfer cylinder 615. And are arranged to remain in a predetermined position with respect to each other when rotating in the direction of the sixth transport nip TN6. The gap between the vacuum conveyor 641 and the third transfer cylinder 615 in the nip TN6 may be used to securely separate the pad from the cut 625 produced in the second cutting nip CN2. ) Should not be greater than the thickness (preferably slightly smaller). The continuous strip of cut 625 material is preferably removed downstream from the sixth transfer nip TN6 and is conveyed to an appropriate waste collector along a path (eg, 645 in FIG. 29). The pad 1 is laminated on the conveyor 641 in a non-folded state with each pad lying flat on the conveyor in the pre-folded position, in which the shielding web 9W faces upward and the cover web ( 7W) faces downward and the long axis A1 of the pad extends substantially parallel to the feeding direction and the pad is centered on the conveyor 641 generally in the transverse (CD) direction with respect to the conveyor.

In order to keep various cutting rolls, sealing rolls, and transfer cylinders in a timed relationship with each other, they are preferably driven by a common drive mechanism. This mechanism includes a drive motor and a drive train connecting the motor to various rolls and cylinders. The drive train may comprise, for example, a series of timing belts and pulleys, or a series of gears or other drive elements, which will be understood by those skilled in the art.

In the embodiment shown in the figures, the axial length of each of the cutting roll, the sealing roll, and the transfer cylinder is sufficient to accommodate only one lane of absorbent body and pad. However, it should be appreciated that for higher productivity, additional lanes can be formed using wider rolls and cylinders that involve changes to the associated equipment.

The vacuum conveyor 641 for conveying the pad 1 to the folding section 33 comprises three endless vacuum belts in one embodiment (FIG. 30), specifically in these belts, first and second slots. Center belt 643 and a pair of side belts arranged in rows around roller 647 with upper horizontals that are generally horizontal, substantially parallel, and generally in a common plane, spaced apart to form (S1, S2) 645 is included (FIGS. 30 and 32). The belts are perforated and relatively narrow, and the overall width of the conveyor is such that the side belt 645 supports each side section 1A, 1B of the pad and the center belt 643 supports the center section of the pad. No substantially greater than the width of the unfolded pad 1 carried by the conveyor. These belts are preferably driven by a common drive 651 (Figure 30). A vacuum box 653 having a vacuum opening 655 on its top surface is mounted directly below the upper reach of the conveyor belts 643 and 645 and communicates with the vacuum system by an air duct (not shown), the arrangement of which A vacuum is generated in the perforations of the center belt and the side belt to hold the pad in the above-described pre-folded position and feed it to the folding station 33. Other means may be used to transfer the pads from the pad making section 31 to the folding section 33.

The pads sent out to the folding station by the conveyor are folded by the folding device 661. In one embodiment (FIGS. 31 and 32), the apparatus is a generally horizontal axis spaced above vacuum conveyor 641 to form a gap 665 between the circumferential edge of the disk and the upper reach of the center belt 643. And a pressing member comprising a rotatable disk 663 mounted to rotate about. The pressurizing disk 663 preferably rotates at the same speed in the same direction as the conveying of the pads, which respectively presses the pads against the center belt 643 when the pads are conveyed and folded through the gap 665. Contact with the pad.

The folding device 661 further comprises a plurality of folding members, which in one embodiment are pressed to rotate about a horizontal axis spaced below the upper reach of the belts 643 and 645. Two folding disks 671 mounted to opposite sides of the disk. As shown in Fig. 31, each folding disk 671 is formed with ramps 675 at intervals around its circumferential edge. The lamps 675 on the two disks 671 protrude upward through the respective slots S1 and S2 between the belts 643 and 645, and are pads 1A and 1B which are conveyed under the pressing disk 663. It is in contact with the side section of the. The folding discs 671 face each other side sections 1A and 1B as shown in Figs. 4 and 32, with each pair of lamps 675 on the two folding discs contacting each pad passing through the gap. It is preferable to rotate in the same direction as the press disk 663 so as to fold in position.

Optionally, each pad 1 may be applied with an adhesive at a suitable location on the pad (eg, spot 679 in FIG. 1) before the pad is folded. One embodiment of this selection is shown in FIGS. 30 and 33, which distributes a metered amount of adhesive (eg, in the form of beads) on an applicator 687 disposed directly above the conveyor 641. Glue dispenser 681 with a nozzle 683 to make it. In the illustrated embodiment, the applicator 687 is generally rectangular in shape, and in the orientation shown, has a relatively narrow upper and lower edge 691 for receiving the adhesive from the nozzle 683 of the dispenser 681.

The applicator 687 allows the conveyor 641 to apply a small area of adhesive to the top surface of each pad at a suitable location as the pad passes under the lower edge 691 of the applicator with adhesive (FIG. 33). It can be rotated by the driven shaft 693 so as to rotate in an appropriate time relationship with respect to the movement of the pad 1 on. The speed at its upper and lower edges 691 of the applicator 687 preferably matches approximately the speed of the conveyor 641. The dispenser 681 intermittently (with appropriate time relationship to the driven shaft 693 to deliver an individual amount of adhesive to the upper edge 691 of the applicator 687 when the lower edge applies the glue below the pad). intermittently) or continuously to deliver adhesive from the continuous beads from the nozzle 683 picked up by the top edge of the applicator as it moves through the beads.

Alternatively, the glue dispenser 681 is arranged such that a nozzle 683 for dispensing the metered amount of adhesive is located near the pad 1 (eg, at a distance approximately less than the diameter of the adhesive bead). The dispenser 681 is intermittently operated to apply the adhesive directly to the product. The pad is preferably maintained at a constant thickness by vacuum force as it passes through the nozzle 683 on the conveyor 641. In one embodiment, glue dispensers sold by Nordson Corporation, Westlake, Ohio, are used. It will also be appreciated that the adhesive can be applied by an applicator having a different shape and / or operating in a different way. Operation of the dispenser and applicator is controlled by a sensor (eg, photocell 697) disposed upstream of dispenser 681 to sense the presence (or lack of presence) of the pad.

In order to accommodate the application of adhesive to the pad 1, the pressurizing disk 663 has a series of openings (eg, notches 701) extending inwardly from its outer edge and spaced around the disk. Have The notches 701 are sized and positioned such that the side sections 1A, 1B of each pad can contact each other at the position of the adhesive spot 679 during the folding process. The adhesive helps to keep each pad in its folded state before the pad is wrapped and after the pad is removed from the wrapper for use.

After the pad 1 is folded, the pad is conveyed to the packaging section 35 of the machine by a suitable conveyor mechanism in the folded state. In one embodiment (FIG. 34), the conveyor mechanism 705 has a spaced reach that defines a gap 713 for receiving the pad 1 discharged from the vacuum conveyor 641 at the folding station 33. And a pair of endless transfer belts 709. The gap 713 is sized such that the conveying belt exerts sufficient force on the pad to grip the pad and transport it to the packaging section 35. In one embodiment, the belts 709 and 711 are twisted 90 degrees to receive the pad 1 folded in a generally vertical orientation and then rotate the pad 90 degrees to feed the packaging section 35 in a generally horizontal orientation.

The two conveying belts 709, 711 are a pair of spaced apart rotatably mounted on a generally horizontal support plate 719 carried by a bracket 721 having a horizontal slot 723 fixed to the frame of the machine. Journaled to rotate in a bearing housing 731 mounted to two brackets 733 having upstream ends formed in a line around a generally vertical roller 717 (FIG. 34), and a slot 735 fixed to the frame. It has a downstream end formed in a line around a pair of generally horizontal rollers 727 rotatably mounted on the shaft 729. The shaft 723 preferably has a sprocket connected to a suitable variable speed motor (not shown) by a timing belt for rotation of the shaft by the motor. Slots 723 and 735 in the various brackets 721 and 733 allow the position of the belts 709 and 711 to be adjusted in the vertical and horizontal directions as needed.

Vertical rollers 717 at the upstream ends of the belts 709, 711 are secured by threaded fasteners 741 received in a transversely extending slot 743 in the support plate 719, which fasteners between the two belts. Can be moved within the slot so that the spacing of the can be adjusted. The pair of belt guide assemblies 747 and 747 maintain the upstream ends of the belts 709 and 711 in their proper position on their respective vertical rollers 717. In the embodiment shown in Figure 34, each assembly 747 mounts a guide roller 751, which is in contact with each belt 709,711, and the support roller 751 on a support plate 719. Linkage.

In the illustrated embodiment, the connecting means is an L-shaped angle bar 755 which is fixed to the lower side of the support plate 719 by threaded fasteners (not shown) received in the slot 757 in the horizontal leg of the angle bar. ), An upper tubular arm 761 having a vertical leg of the angle bar and a pivot connection 763, a lower arm 765 elastically fitted to the upper arm 761, and the upper and lower arms relative to each other. A locking collar 767 for fixing in a fixed longitudinal position and a rotational position, and at its lower end a pivot connection 783 with the lower arm 765 and at its upper end a guide roller 751 is rotatably mounted. A lever 781 having a pivot connection 785 with a roller support 787. By means of said connecting means the position of the guide roller 751 can be adjusted in at least three different dimensions, ie using the slot 757 in the angle bar 755 to change the position of the bar relative to the support plate 719. Thereby in the first dimension corresponding to the machine direction MD, in the second dimension corresponding to the Z direction about the pivot connection 763, the upper and lower arms 761 and 765 to elevate the guide roller 751, And can be adjusted in a third dimension by rotating the lower arm 765 on its longitudinal axis relative to the upper arm 761 to swing the guide roller 751 to an angular position whose axis of rotation is angled with respect to the vertical plane.

By using one or more of these adjustments, the guide roller 751 prevents the belt from "walking" up and down on its respective vertical roller 717 to keep the belt nearly centered on the roller. It may be arranged to contact its respective belts 709 and 711 in any orientation required. The spacing between the belts at its downstream ends can be varied by using the slots 735 in the bracket 733 to adjust the position of the horizontal roller 727. The downstream end of the transfer belt is disposed immediately adjacent to the packaging section 35 for feeding the pads to the wrapping device 801.

Referring to Figures 29 and 35, the wrapping device 801 includes a forming apparatus 805 for receiving pads sent out by the transfer belts 709 and 711, and a web disposed downstream of the forming apparatus 805. Traction means 807, wherein the web-towing means is adapted to move the forming apparatus from a supply roll 813 of such material to a continuous web 811 of flexible wrapping material (e.g., polyethylene or other suitable material). Pulled past, the pad 1 is wrapped in a tube 815 of material that will later form a wrapper for the pad when sealed and cut. The supply roll of packaging material is supported by a shaft 821 driven by a variable speed motor (not shown) to control the speed at which the web is fed from the roll. The speed of the motor is controlled by the web-tension sensing device 827 similar to the sensing device described above for the unwind rolls 425 and 427. When the sensing device detects a change in web tension, it sends a signal to the motor to rotate the shaft 821 slower or faster to keep the speed at which the web 811 is pulled out of the roll 813 is nearly constant. send.

36-40, the forming apparatus 805 is an angled fold edge (contacted by each opposing side edge M1, M2 of the web 811 as the web is pulled past the fold edge (FIG. 36). First and second web fold members 831, 833 having 831A, 833A, web guides 837 for guiding the web toward the fold edge, and the center of the web when the web is towed past the forming device An opening 839 between the web guide and the folded edge to be squeezed. In one embodiment, the folding member has upper and lower folding plates having opposing surfaces defining a relatively narrow gap 843 (FIG. 40) extending in the machine direction MD when the web is pulled over the forming apparatus 805. FIG. Or boards 831 and 833. The folding members 831, 833 also have spaced sidewalls 847 that extend downwardly outward from their respective folding plates. The fold edges 831A, 833A at the upstream ends of the plates 831, 833 are in opposite directions with respect to the web movement direction and at an appropriate angle with respect to the web movement direction, preferably about 14 ° to about 20 °, more Preferably it forms an angle in the range of approximately 16 ° to approximately 18 °. The folding member may have a configuration different from that described above.

Web guide 837 includes a generally triangular web contact surface or wall 851 with base edge 853 and opposite side edges 855 tapering upward toward vertex 857 in the embodiment shown in FIG. do. The wall 851 is inclined with respect to the plane of the opening 839 and is arranged to be contacted by a web 811 of packaging material pulled from the feed roll 813. Tongue 861 extends from vertex 857 toward opening 839. The tongue 861 is preferably coplanar with the lower fold plate 833 or spaced below the fold plate by a vertical distance less than or equal to the thickness of the pad. The web guide also has a sidewall 865 extending downstream from each folding edge 855 to an integral connection with each sidewall 847 of the folding member. For the sake of economy, the web guide and the folding member may preferably be formed as a single piece of curved sheet metal (eg, 14 gauge 304 stainless steel sheet), although it may consist of separate parts.

36 and 38, the tapered folding edge 855 of the web guide 837 initiates folding of the web 811 and contacts the web by the angled folding edges 831A, 833A. ) To guide towards the folding boards (831, 833). A pair of notches 869 extend downward from the vertex 857 of the wall 851 of the web guide on the opposite side of the tongue 861. When under tension, the web 811 deforms downward into the notch 869 as it is pulled past the forming apparatus 805.

The wrapping device 801 is preferably provided with what may be referred to as a force-applying device, which in a preferred embodiment extends over the forming device 805 generally along the center of the web 811. And a relatively short narrow endless belt 875 (the purpose of this belt will be described later). The belt 875 is supported by a pair of rollers 877 and 879, one or both of which rollers move the belt 875 at the same speed as the web 811 moving past the forming apparatus 805. It is driven to move. In the embodiment shown in Fig. 41, an upstream roller 877 is mounted on a driven shaft 881 rotatable in a bearing housing 883 fixed to the frame of the machine by a bracket 885 with a slot 877. . The downstream roller 879 is rotatable in the bearing housing 891 carried by the support plate 893. The support plate 873 includes a support plate and a downstream roller 877 with respect to the bearing housing 883 for changing the position of the belt 875 as necessary for maintenance and adjustment to the forming apparatus 805. A power actuator (e.g., power cylinder 895) for pivoting is connected.

Referring to Figure 38, an upstream end of the endless belt 875 is disposed above the web guide 837 to form a gap 901 for receiving pads from the transfer conveyor 705. The pads fed one at a time into the gap 901 are conveyed by the moving web 811 and the belt 875 across the opening 839 in the machine direction MD and past the folding boards 831, 833. In the embodiment shown in the figures, the upstream roller 877 of the belt 875 is disposed over the vertex 857 and tongue 861 of the web guide 837, and the downstream roller 879 is generally above the opening 839. Is placed. The lower reach of the belt 875 is inclined downward in the machine direction MD and forms an inclined surface which is arranged to contact the pad. Thus, as each pad 1 moves past the tongue 861 over the opening 839, the pad is pressed down against the web and moved to a level where it will pass under the lower fold plate 833.

This downward force “cups” the web in the area of the opening 839 so that a pocket or recess 905 is formed in the web to support the pad. This cupping action is such that, in a preferred embodiment, the web may be formed by elastic compression of the pad, for example, to the point where the pad has a thickness in the range of 50 to 100% of its uncompressed thickness, more preferably approximately 95% or more. It is preferable to involve elastic deformation or stretching. As a result, the web 811 is tightly wrapped around the pad as the web is pulled past the folding edges 831A, 833A of the folding plates 831, 833 to form the tube 815 around the pad. In addition to applying a downward force in the Z direction, the friction between the belt 875 and the pad 1 causes the pad to be pushed in the machine direction MD to help the pad move toward the folding board.

38A-38C show another force-applying device 918 for exerting a downward force on the pad. The apparatus is disposed on a web guide 837 and includes a press plate 920, which press plate 920 defines a downwardly extending side flange that forms a channel 922 for receiving pads from the transfer conveyor 705. 921). Pads fed one at a time into the channel 922 are carried across the opening 839 and past the folding boards 831, 833 in the machine direction MD by the moving web 811. In the embodiment shown in the figure, the pressure plate 920 has a bottom surface inclined downward in the machine direction MD and arranged to contact the pad. Thus, as each pad 1 moves past the tongue 861 and over the opening 839, the pad contacts the lower surface of the pressure plate 920 and is pressed downward against the web 811, which, as described above, has a lower fold. It is moved to a level that will pass under the plate 833.

As shown in FIG. 38A, the pressure plate 920 is used to move between the lowered position shown in FIG. 38A and the raised position (not shown) in which the pressure plate is properly positioned relative to the web guide 837. FIG. Is carried at the lower end of the rigid arm with the upper end pivoted against the frame of the machine, the two ranges of pivot movement being defined by two stops 936 and 938. The torsion spring 928 forces the arm to its lowered position. In one embodiment, a proximity switch (not shown) is mounted near arm 923. The backup or jammed state of the pad 1 in the channel 922 results in an upward force on the pressing plate 920 and also causes a corresponding movement of the arm 923 to pressurization of the spring 928. Cause. This movement triggers the proximity switch to change the operator in the jammed state or to stop the movement of the transfer conveyor 705.

Preferably, as shown in FIGS. 38B and 38C, the apparatus 918 is also disposed on a pressure plate 920 to form a plenum chamber thereon (eg, plate 930). ), And an air contact 929 on the plenum member 930 for supplying compressed air from a suitable source to the plenum chamber. An air hole 934 is drilled in the pressure plate 920 through which air is moved to form an air film between the pressure plate 920 and the pad 1 as the pad passes under the plate. The air membrane reduces the friction between the pad and the pressure plate 920 as the pad moves toward the folding boards 831, 833. It will also be appreciated that other devices may be used to apply the aforementioned pressing force on the pads.

Web guides 837, openings 839, and folding members 831, 833 shown in the figures may have other shapes within the scope of the present invention. For example, the length and shape of the tongue 861 may vary. In addition, the opening 839 has a width W of approximately 97% of the width of each pad in the transverse direction (CD) (transverse to the web moving direction) and a machine direction (MD) of approximately 18% of the length of each pad. ) Length L, but the size of the aperture can be varied.

It is preferable that the position of the forming apparatus 805 can be adjusted in the machine direction MD, the transverse direction CD, and the Z direction. This adjustment can be accomplished in various ways, but one such method is shown in FIG. In this particular embodiment, the forming device 805 is mounted on a post 909 fixed at its lower end to a channel 911 extending in the machine direction MD. The channel is then attached to a transverse rail 915 supported by a mounting plate 917 having a slot 919 fastened to the frame of the machine. The channels and rails 911, 915 are provided with fastener openings for adjusting the forming device in the MD and CD directions, and the slot 919 provides adjustment of the device in the Z direction. Therefore, the position of the forming apparatus can be adjusted in the MD, CD, and Z directions as necessary.

Referring to FIG. 38, the forming apparatus 805 includes a web of 811 when the pad is folded out of the forming apparatus 805 before or when folded to secure the tube 815 around the pad 1. An adhesive applicator 925 is provided for applying a suitable adhesive to at least one edge M1, M2. In one embodiment, the applicator 925 applies adhesive to the edge M1 of the web as the web moves past the nozzle 931 and before the edge M1 of the web overlaps the opposite edge M2 of the web. A gun capable of dispensing an appropriate adhesive (e.g. hot melt glue) through a nozzle 931 disposed close to the web 811 (e.g., 0.003 to 0.004 inches (within 0.0762 to 0.1016 mm) for transfer. 927. The nozzle conveys a continuous bead or stripe of adhesive to the web, as shown in Figures 933 to 36, but the adhesive may be applied intermittently to the web if necessary. The adhesive dispensed from 931 is preferably in the form of extruded beads, but may also be sprayed In one embodiment, the air supply line 932 provides a pressure source for opening the gun 927 and the air supply line ( 934 closed gun 927 To provide a pressure source.

In the embodiment shown in Figures 42-44, the applicator is connected to an adhesive supply line 937 for delivering the adhesive to the gun, and optionally delivers air under pressure to dispense the adhesive through the nozzle 931. And a housing 935 connected to a pressure air line (eg, 20 psi (1.38 bar) air). The position of the nozzle can be adjusted in the Z direction to change the spacing between the nozzle and the web as needed.

42-44 illustrate one possible way to achieve this adjustment. In this particular embodiment, the housing 935 of the applicator is attached to a crosshead 949 that bridges the piston rods 953 of the power actuator 957 by a bracket 945 having a slot 947. . The actuator is then mounted to the slidable tongue 961 in the vertical groove 963 of the mounting block 965 attached to the L-shaped bracket 947 secured to the frame. The rotatable screw shaft 971 (FIG. 44) in the mounting block 965 extends through the screw hole 971 of the tongue 961, and the arrangement of the screw shaft 971 by the handwheel 975. Rotation is made to move the tongue and actuator 975 in the vertical direction. Accordingly, the Z-direction position of the adhesive applicator 925 can be roughly adjusted by the expansion and contraction of the piston rod 953, and can be more finely adjusted by the rotation of the handwheel 975.

Once the gap between nozzle 931 and web 811 is set, thumbscrews 979 screwed through bars 981 secured to brackets 967 are screw shafts until further adjustment is required. Tighten against handwheel 975 to lock 971 to rotation. The bracket 967 holding the mounting block 965 has a horizontal slot 985 (FIG. 42) so that the position of the nozzle 931 can be changed in the direction of the CD extending across the web. Adjustment in the MD direction is made by the slot 947. Other mechanisms may be used to adjust the position of the applicator 925 relative to the web 811.

Alternatively, an adhesive gun 927 may be placed to dispense the adhesive so that it is applied to the opposite edge M2 of the web after the web is folded to the pad rest position but before the edge M1 is folded face to face with M2. have. The lower folding board 833 may be provided with a notch (not shown) for this purpose. A portion of this notch extends upstream from the angled fold edge 831A of the top fold board 831 to expose the folded edge M2 of the web for adhesive application from the gun 927. After the adhesive is applied, the upper fold board 831 folds the other edge M1 of the web over the underlying edge M2 as the web is towed past the fold board.

A web-towing means 807 for pulling the web 811 past the forming apparatus 805 is in an embodiment (FIGS. 35 and 45) endlessly arranged in line around the upstream and downstream rollers 1007, 1009. A vacuum conveyor 1001 in the form of a perforated belt 1003 (perforations omitted for simplicity in FIG. 45), wherein at least one of the rollers (e.g., roller 1007) is a bracket 1015 on the frame. It is rotated by a drive shaft 1011 mounted to a bearing housing 1013 fixed to it. Under the upper reach of the belt 1003, the frame is supported by a vacuum box or manifold 1019, which holds the belt to grip the tubular wrapper 815 formed by the forming apparatus 805. Induces a vacuum, thereby providing the force necessary to pull the web 811 in the machine direction (MD) above the forming apparatus, including pads from the forming apparatus 805 to the wrapper sealing station 1025 downstream. In order to supply the tubular wrapper, it has an opening 1021 on its upper surface.

The conveyor 1001 also has an upper endless compression belt 1027 supported by upstream and downstream rollers 1029 and 1033, respectively. As shown in Figure 45, the upstream roller 1029 is driven by a rotatable shaft 1035 in a bearing housing 1039 that is secured to a bracket 1041 fastened to the frame of the machine. The downstream roller 1033 is supported by a shaft 1041 journaled to a bearing plate 1045 having a pivot connection 1047 with a bearing housing 1039. As shown in FIG. 35, the compression belt 1027 moves between the lower position of the belt and the lowered position having a drop slope that is substantially parallel to or smaller than the upper reach of the lower belt 1003, and the raised position shown in FIG. To this end, the bearing plate 1045 may be pivoted around the connection by a power actuator (eg, cylinder 1051). When in its lowered position, the compression belt 1027 presses together the overlapping edges M1 and M2 of the wrapper to form a good adhesive seal along the tube and also to assist the wrapper feed in the machine direction MD. A compressive force is applied to 815. Compression belt 1027 may be raised for maintenance when not in use.

The sealing station 1025 has a sealing device 1100 (FIG. 35) for sealing the tubular wrapper 815 between the pads 1 in a sealing region 1103 extending transversely in the CD direction (FIG. 46) with respect to the tube 815. ) Is provided. Referring now to FIGS. 35 and 47, the sealing device 1100 includes upper and lower sealing rolls 1107, 1109, each of which is axially along the circumference of the roll at intervals spaced around the roll. There are a number of sealing jaws 1113 extending (e.g., six sealing jaws spaced 60 ° around the roll). Each jaw 1113 is a sealing bar 1121 having a base 1117 fastened to the roll by a threaded fastener 1119 in a conventional manner, and a sealing area 1125 protruding from the base and heated. It includes.

The bar is embedded with a heating member (not shown) for heating the sealing region 1125 of the bar to a temperature sufficient to soften the wrapper material. The rolls 1107 and 1109 are driven by an appropriate drive mechanism 1131 to rotate in a timed and synchronized relationship with each other, so that the heated sealing jaws 1113 on the two rolls are mated sequentially and simultaneously along the web. The opposing (eg, top and bottom) surfaces of the tubular wrappers 815 are spaced apart to press them together and form a sealing region 1103 between the pads, as those skilled in the art will understand. Operation of the heating element is controlled by a temperature sensor embedded in the sealing bar 1121 in the vicinity of the heating element. Preferably, the sealing area 1125 of the sealing bar 1121 mechanically deforms the opposing surfaces of the tubular wrapper 815 and forms a mechanical bond therebetween to texturize them to maintain them together prior to the complete cooling of the seal. (Eg, roughening). Immediately upstream of the sealing rolls 1107, 1109 is provided a support surface 11131 for supporting the tubular wrapper as it enters the nip of the roll.

The tubular wrapper 815 is sealed two by suitable means, such as a pair of top and bottom endless belts 1135 and 1137, similar to the endless belts 1003 and 1027 described immediately upstream of the sealing station 1025. Pulled between the rolls 1107 and 1109. These belts 1135 and 1137 also act to feed the sealed wrapper 815 to the cutting station 1041, which has a separate pad wrapped by cutting the sealed tubular wrapper in the sealing area 1103. There is provided a cutting device 1043 for forming a die.

Referring to Fig. 29, the cutting device 1043 includes a pair of top and bottom cutting rolls 1051 and 1053, respectively, in one embodiment. The construction of these rolls is sealed except that the sealing jaws on one roll are replaced by cutting blades and the sealing jaws on the other roll are replaced by anvil bars supporting the web for cutting by the blades in a conventional manner. Similar to rolls 1107 and 1109. As schematically shown in FIG. 46, the cuts 1061 across each seal area are generally (in the machine direction MD) of the seal such that one cut forms simultaneously the trailing seal of one wrapper and the tip seal of the subsequent wrapper. It is formed in the middle. The individually wrapped pads are then discharged into a suitable receptacle 1065 (FIG. 16) or on a conveyor and transported to an optional tracking station where the pads can be further packaged in a carton or the like by hand or a suitable tracking mechanism. Can be grouped.

The operation of the foregoing apparatus for carrying out the method of the present invention is now described. Raw fibers (e.g., cotton and rayon) are weighed and mixed in a proportion in the fiber mixing section 21 of the system. This process is loaded onto the in-feed conveyor 67 of the first metering device 41 (FIG. 7) for feeding fibers of one material (e. G. Cotton) to its respective meter. And load the fibers of another material (e.g. rayon) onto the infeed conveyor of the second metering device 43 for delivery to its respective meter. The meter 77 can be operated to unload on the conveyor 91 to meter the amount of these fibers in the correct weight ratio (e.g., 1120 grams of cotton and 480 grams of rayon) and send them to the blend opener 47. have.

In one embodiment, the unloading is timed such that the downstream meter 77 unloads its metered fiber bundle directly onto the fiber bundle unloaded by the upstream meter 77, and thus contains a bundle of fibers comprising the correct proportion of fiber. Is sent to the blend opener 47 (FIG. 8). The fibers fed to the blend opener are opened and mixed to some extent and then transferred to the air separator 51 through the air duct 49 (FIG. 9). There, air and fine fibers are separated from the long fibers and sent to the fine fiber collector 57. The long fibers are conveyed to the rotary air lock 144 which rotates at a speed necessary to supply the long fibers to the inlet of the fine opener 55 at a predetermined speed. The fine opener 55 (FIG. 10) further separates and blends the fibers and feeds them through the air duct 61 to the feed chute 221.

Fibers entering the inlet section 229 of the feed chute 221 (FIG. 11) are entrained in an air stream and moved to the upper chute 231 where they are collected over the feed and beater rolls 245 and 247. Air entering the upper chute 231 exits through the porous wall 237 of the chute. The feed and beater rolls 245 and 247 rotate to perform a separation and mixing operation on the fibers before they are sent to the accumulation chute 263 in a state where the fibers are almost separated (“open”) and mixed. Fibers in the form are mixed with fibers in the other forms. The downward supply of fibers in the accumulation chute 263 is assisted by the shaking of the shaker plate 267. In addition, the frequency and amplitude of the swing can be changed to control the density of the fiber sent to the compression roll 291 near the outlet 227 of the feed chute.

As the fiber passes between these two rolls 291, the fiber is formed into a layer 295 of predetermined thickness to be loaded into a conveying device 301 leading to the forming section 27 of the machine (FIG. 13). The thickness of the layer 295 and the speed at which it is sent out are controlled by the size of the gap 293 between the compression roll 291 and the speed of the roll, respectively. For example, layer 295 may have a thickness of approximately 2 inches (5.08 cm) and the roll may have a surface speed of approximately 6 fpm (1.83 m / min). The density of the layer 295 (eg, weight per unit length) is determined by the height of the fiber column in the accumulation chute 263, the amplitude and frequency of the fluctuations of the shaker plate 267, and the compressive force exerted by the compression roll 291. , And at least in part by the speed of the roll 291. Preferably, the density of the fibers released from the feed chute 221 is in the range of 0.005 to 0.16 g / cc, more preferably in the range of 0.010 to 0.030 g / cc, most preferably in the range of 0.013 to 0.019 g / cc. have. The layer 295 of mixed fibers sent out from the feed chute 221 can vary considerably in dimensions but can be relatively wide, such as for example 40 inches (101.6 cm) wide. When sufficiently dense, layer 295 may be in the form of an integral web capable of independently maintaining its body and shape. However, the layer can also be the thickness of the loosely dense (or not dense) fibers whose shapes are combined to form a non-independent body.

The layer of fiber 295 from the feed chute 221 lowers the slide 301 to gravity (or slightly different) to be fed into the gap between the feed roll 315 and the adjacent guide surface 317 as shown in FIG. Is conveyed by an endless conveyor in such a way). The rotating feed roll 315 serves to feed the layer 295 of blended fibers to a fiberizing roll (eg, liquor roll 321) that breaks the fibers. After this fiberization operation, the fibers are swept away to the inlet of the air chamber 347, where they are airlaid to the forming surface 337 of the conveyor 335, and within the absorbent body in the pad (eg, in the pad 1). It is reformed into a layer 343 having a width that substantially matches the final width of the body 5. As mentioned above, the fibers that make up this reformed layer 343 are irregularly oriented, mixed into a nearly homogeneous mixture with strength in the MD and CD directions, and further effectively absorbing and distributing fluid deposited on the material. Have the ability. The thickness of the reformed layer 343 is controlled by the variable speed of the reforming conveyor 335 and the amount of fiber sent to the air chamber 347 to be laminated to the porosity forming surface of the conveyor.

When so reformed, the layer 343 is transferred to a compression belt 401 where the fibers are lightly compressed and then to compression rolls 407 and 409 where the fibers are compressed more severely so that the final product (Fig. The continuous web 417 of an absorbent material having a thickness that generally corresponds to the thickness of the absorbent body (eg, the body 5) in 17). The compression belt 401 may be removed if not needed. The thickness of the web 417 is mainly controlled by the spacing between the two compression rolls 407, 409. After compression, the web is transferred to the pad making section 31 of the system.

In the pad manufacturing section (FIG. 18), the web 417 is fed in the machine direction MD between the two cutting rolls 451, 453 at the first cutting station 431, in which the web is An exemplary shape is cut to form the individual absorbent body 5 shown in FIG. The web is then vacuum conveyed by the knife roll 451 to the first conveying nip TN1 in which the absorbent bodies are conveyed to the first conveying cylinder 485 while maintaining the correct position relative to each other. . The cut (waste) 491 from the cutting operation is preferably sent by the vacuum duct 493 and then removed and sent to a suitable collector (not shown). On the other hand, the absorbent body 5 is vacuum transferred to the second transfer nip TN2 by the first transfer cylinder 485.

The cover web 7W is also fed from the unwinding roll 425 to the second transfer nip TN2, in which the body 5 is connected to the sealing roll 541 from the first transfer cylinder 485. It is continuously conveyed to a position on the cover web overlying each pocket 553. The body 7 and the web 7W constituting the base 5 are pulled into the pocket 553 by the vacuum opening 561 and held in place when transported to the sealing nip SN. If the shielding web 9W is used, it is combined with the cover web 7W and the absorbent body 5 in the sealing nip SN as described above (Fig. 19), and the sealed laminated web 437 is then subjected to the third transfer nip. Vacuum transfer to TN3, and transfer to second transfer cylinder 571 in the third transfer nip. The second transfer cylinder 571 vacuum grips the laminated web and transfers it to the fourth transfer nip TN4, where the web 437 is a second cutting nip in the second cutting station 441. It is conveyed to the lower cutting roll 607 to be vacuum conveyed to CN2. There, two cutting rolls 607, 609 cut the laminated web 437 around the absorbent body 5 to form individual pads (eg, pads 1), which are formed by the web. 5 is retained by the vacuum opening 617 in the lower roll 607 when conveyed to the transfer nip TN5. The pad 1 is transported to the third transport cylinder 615 at TN5, which transports the pads, with the pads shielded layer 9 of the pad facing up (if a shielding layer is used). In an orientation in which the pad is preferably laid flat on the conveyor, with the central portion of the pad supported by the center belt 643 and the side sections 1A, 1B of the pad supported by the side belt 645. Stack on 3-belt vacuum conveyor 641. The cut or waste portion of the web 625 (FIG. 28) can be traced around the third transfer cylinder 615 such that the cut is sent to a suitable collector, or the cut is taken to the fifth transfer nip for disposal. It is removed by pulling straight down from TN5.

The vacuum conveyor 641 transfers the pads 1 to the folding section 33 while maintaining a fixed position relative to each other. In the folding section (Fig. 30), the side sections 1A, 1B of each pad are folded up by two folding disks 671, and the central section thereof is pressed by the pressing disk 663. When so folded, the pads appear as shown in Figure 3, and the pads are preferably placed in a generally upright (eg vertical) orientation. Prior to folding, an adhesive, such as a hot melt glue, may be applied to the top surface of the pad (eg, the shielding layer 9) by an applicator 687, whereby the two side sections 1A, 1B are face to face. When folded, the adhesive holds the pads folded. After each pad 1 is folded, while the pad is still held upright by the folding disk 663, the gap 713 between the conveying belts 709 and 711 is conveyed to the packaging section 35 (FIG. 34). Supplied by. The 90 ° twist of the belts 709, 711 serves to rotate the pad 1 in a generally parallel orientation for delivery to the forming apparatus 805. The position of the guide roll 751 can be adjusted if necessary to keep the torsion belt properly centered on the vertical roller 717 at its upstream end.

In the packaging section 35, the web 811 of flexible wrapping material is towed by the web-towing means 807 onto the forming apparatus 805, which is first advanced above the web guide 837 and then folded on the folding board. Advance past 831, 833 (FIGS. 36 and 38). When the web 811 is towed over the forming apparatus, the pads 1 are fed from the transfer belt 709 into the gap 901 between the tongue 861 of the web guide and the overhead belt 875 one at a time, and over The head belt moves at the same speed as the web. As each pad enters this gap, it is transported with the web in the machine direction MD over the opening 839 between the tongue 861 and the folding boards 831, 833. As the pad moves over the opening 839, the downwardly inclined lower reach of the belt 875 forces the pad 1 to press the pad to the center of the web 811, making the web cup-shaped, preferably Is somewhat elongated in the transverse direction (CD) as best shown in FIG. This cupping of the web creates a volume, ie a recess or groove or pouch 905 in the web to begin forming the tubular wrapper 815 around the pad. The force applied to the pad 1 is sufficient to move the center of the web 811 and the base of the web downward to a position where the top of the pad will clear the lower folding board 833. This position can be adjusted by the operation of the power cylinder 895 to pivot the belt 879 up or down relative to the folding device 805. As mentioned above, other force-applying devices (eg, inclined fixed surfaces) may be used to begin forming the tubular wrapper 815 around the pad.

When the central portions of the pad 1 and the web 811 move below the lower folding board 833, the side edges M1 and M2 of the web join each of the folding edges 831A and 833A of the folding board, and FIG. 40 As shown in FIG. 1, the tubular wrapper 815 is formed around the pad by being folded in a face-to-face relation. In the embodiment shown in Figure 40, the side edges M1, M2 of the web are folded such that their facing surface consists of opposing faces of the web 811 to form a so-called overlapping seam on the tube 815. However, it should be noted that the side edges M1 and M2 can be folded to produce a fin seam consisting of the same side of the web 811. In either case, an adhesive 933 is applied to at least one of these edges by an applicator 925 before the side edges M1, M2 are folded in a face-to-face relationship, and the adhesive is eventually opposed after the folding operation is completed. It is placed on the surface of the side edge that will face the side edge. The spacing between which the adhesive is applied between the nozzles 931 of the applicator 925 and the surface of the web 811 is such that the web has a uniform volume of continuous beads (or uniform volume) from the nozzle as the web passes through the nozzle. It is preferably made to tow a series of intermittent spots. Alternatively, the adhesive may be sprayed or otherwise applied to web 811.

The tubular wrapper 815 comprising the pad 1 is pulled in the machine direction MD by a vacuum belt 1003 (FIG. 45), in which the vacuum belt forms a web 811 in a preferred embodiment. Provide the main force for towing up. When the newly formed tubular wrapper 815 passes between the vacuum belt 1003 and the overhead compression belt 1027, the wrapper receives a compressive force to bond the side edges M1 and M2 of the web together and the tube is sealed. A longitudinal seam extends by the length of the tubular wrapper before being fed between the two sealing rolls 1107, 1109 at the station 1025. As the two seal rolls rotate, the seal bar 1121 on the top roll 1107 moves in series with the seal bar 1121 on the bottom roll 1109 to move the tube into the seal area 1103 between the pads (FIG. 46). Seal in. The tubular wrapper tube comprising the pad is pulled through the sealing station 1025 by the compression belt 1135 and the vacuum belt 1137 downstream of the sealing station. These belts also serve to feed the sealed tubes to the cutting station 1041, in which the cutting rolls 1051 and 1053 cut the tubes laterally in the sealing area 1103 to form individual wrapped pads. do. As mentioned above, additional packaging operations may be performed if necessary.

For efficiency, the various sections of the apparatus of the present invention should be operated at a suitable speed that allows for nearly continuous operation (at least 85% of time) of all sections without interruption. That is, the upstream section must not operate at an extremely high speed that exceeds the capacity of the downstream section, nor should it operate at an extremely low speed that will starve the downstream section.

Although the apparatus and method have been described for producing interlabial pads of the type shown in FIG. 1, features of the present invention may be used to make other types of absorbent or other articles.

The articles used in representing elements of the invention or its preferred embodiment are intended to mean that one or more such elements exist. The terms "comprising", "including", "having" are inclusive meaning to mean that there may be additional elements other than the listed elements.

In view of the above, it can be seen that the various objects of the present invention are achieved and other advantageous results obtained.

As various changes could be made in the above structures and methods within the scope of the present invention, all matters described in the above and shown in the accompanying drawings are to be regarded as illustrative and not restrictive.

Claims (153)

An apparatus for producing a folded interlabial pad, each having a fluid-absorbent body laminated with at least a first cover layer of fluid-permeable material, At least one of which is a mixing device for mixing fibers of different materials that are absorbent and for conveying the mixed fibers to a fiber collection station, A collecting and feeding device disposed in a fiber collecting station for collecting and feeding the mixed fibers to a forming station, Forming apparatus for forming a continuous mixed-fiber web with the mixed fibers disposed at a forming station, A pad for cutting the fluid-absorbent body in the mixed-fiber web, laminating the body with at least one continuous cover web to form a laminated web, and sealing and cutting the laminated web to produce the interlabial pad- Manufacturing apparatus, and An interlabial pad manufacturing apparatus comprising a folding device for folding each pad along its major axis. The apparatus of claim 1, wherein the mixing device comprises a first metering device for metering and releasing a first amount of first fibers, a second metering device for metering and releasing a second amount of second fibers, and the first metering device. An interlabial pad manufacturing device comprising a device for opening and mixing the first and second fibers released from the first and second metering devices. The apparatus of claim 2, wherein the apparatus for opening and mixing the first and second fibers comprises a housing having an inlet for entry of the fiber, a housing having an outlet, and rotatable within the housing. A blend opener comprising a beater roll for releasing through the outlet, and an inlet for receiving fibers from the blend opener, a housing having an outlet, and rotatable within the housing, further opening and mixing the fibers. And a fine opener including a coating roll for discharging through an outlet and transferring to the fiber collection station. The apparatus of claim 3, wherein the collecting and feeding device is arranged at an inlet, an outlet for receiving mixed fibers from the fine opener, an accumulating chute for accumulating a fiber column and being disposed between the inlet and the outlet, and An interlabial pad manufacturing apparatus comprising supplying means for supplying fibers from the column through the outlet as a fiber layer. The interlabial pad manufacturing apparatus according to claim 1, wherein the collecting and feeding device is operable to collect the mixed fibers and supply them to the forming apparatus as a continuous mixed fiber layer. The apparatus of claim 1, wherein the collecting and feeding device is operable to supply an initial layer of mixed fiber to a forming station, The forming apparatus, A fiberizing apparatus for crushing the initial layer into fibers, and An interlabial pad manufacturing apparatus comprising an apparatus for reforming the fibers of the crushed layer as a layer of reformed mixed fibers. 7. The device of claim 6, wherein the fiberizing device comprises a rotatable roll having teeth and a supply mechanism for supplying the layer to the teeth. 8. The forming apparatus of claim 7, wherein the forming apparatus comprises: an air chamber having an inlet and an outlet for receiving fibers of the fibrous initial layer, a reform conveyor near the outlet of the air chamber, and a direction toward the reform conveyor in the air chamber. And an air system for generating an air stream to be directed to direct the fibers onto the conveyor. 9. The interlabial pad manufacturing apparatus of claim 8, wherein the forming apparatus further comprises a compression device for compressing the reformed layer to a predetermined thickness to form the mixed-fiber web. According to claim 1, The pad manufacturing apparatus, Apparatus for feeding a continuous mixed-fiber web to a first cutting station, First cuts for forming individual fluid-absorbent bodies in the webs disposed in the first cutting station and cut through the mixed-fiber webs fed through the first cutting nips and arranged in position relative to each other. Device, A rotatable first vacuum transfer cylinder for transferring the fluid-absorbing body relative to each other while transferring from the first cutting station to the sealing station, A sealing device disposed in said sealing station and defining a sealing nip, A first web supply device for supplying the at least first cover web to be laminated with the fluid-absorbing body to form a laminated web and for passing the laminated nip to seal the laminated web by the sealing device, and And a second cutting device disposed at a second cutting station, the second cutting device for cutting the sealed laminated web to form an interlabial pad. 11. The interlabial pad manufacturing device of claim 10, further comprising a second transfer cylinder for transferring the laminated web from the sealing station to the second cutting station. 11. The cutting device of claim 10, wherein the first cutting device comprises a first cutting roll having an outer surface formed with a vacuum opening for holding the fluid-absorbing body in the predetermined position, wherein the cutting roll is a fluid-absorbing body. And an interlabial pad manufacturing device rotatable for transferring the first cutting nip from the first cutting nip to the first vacuum transfer cylinder. 13. The method of claim 12, wherein the first cutting roll comprises: at least one cutting blade having a perimeter corresponding to the shape of one of the fluid-absorbent bodies, and an elastically compressible insert provided in the perimeter on the cutting roll. A insert, wherein the insert is compressed when a mixed-fiber web is fed through the first cutting nip, and then the elasticity of the insert is applied to the fluid-absorbing body cut in the web by the cutting blade. An interlabial pad manufacturing device that is adapted to push outward. 13. The method of claim 12, wherein the first vacuum transfer cylinder has an outer surface with a vacuum opening formed therein, wherein the first vacuum transfer cylinder and the first cutting roll comprise a fluid-absorbing body at the first cutting roll. And a first conveying nip for conveying to said first conveying nip, said first vacuum conveying cylinder being rotatable for conveying towards a second conveying nip while maintaining a fluid-absorbing body in said predetermined relative position. 15. The sealing device of claim 14, wherein the sealing device comprises first and second sealing rolls, at least one of which has a recess on its outer surface for receiving the fluid-absorbing body transferred to the sealing nip. , Wherein each recess has a shape generally corresponding to a fluid-absorbing body to be received therein. 16. The device of claim 15, wherein the first sealing roll is rotatable for transferring the sealed laminated web to the third transfer nip while maintaining the sealed laminated web in a predetermined position on the sealing roll. 17. The interlabial pad of claim 16, further comprising a second transfer cylinder rotatable for transferring the third conveying nip from the third conveying nip toward the fourth conveying nip while maintaining the sealed laminated web in a predetermined position on the second conveying roll. Manufacturing device. 18. The device of claim 17, wherein the second cutting device includes a second cutting roll having a vacuum opening on its outer surface, the second cutting roll holding the sealed laminated web at a predetermined position on the second cutting roll. Interlabial, rotatable to transfer from the fourth transfer nip to the second cutting nip of the second cutting station, the second cutting device operable to cut the sealed laminated web in the second cutting nip to form the pad Pad manufacturing apparatus. 19. The method of claim 18, further comprising a third vacuum transfer cylinder, wherein the second cutting roll comprises a second cutting roll and a third vacuum transfer cylinder from the second cutting nip while maintaining the pad in a predetermined position relative to each other. An interlabial pad manufacturing device rotatable for transfer to a fifth transfer nip between. 20. The second web supply apparatus of Claim 19, wherein a second cover web is laminated with the first cover web and the fluid-absorbent body to form a laminated web with a fluid-absorbent body disposed between the cover webs. And the laminated web is adapted to pass through the sealing nip for sealing thereof. 11. The apparatus of claim 10, further comprising a conveying device for conveying a series of said pads one by one to a folding station, and a folding device disposed at said folding station for folding each pad. A pressing member which is brought into contact with its central section when conveyed forward, and each pad when disposed on opposite sides of the pressing member and the pad is conveyed forward and folded to a position where the side sections face each other by the pressing member. An interlabial pad manufacturing device comprising a pair of folding members in contact with the side sections of the device. The device of claim 1, further comprising a device for wrapping each pad after being folded at the folding station. The method of claim 22, wherein the wrapping device, A forming device in which a web of flexible wrapping material is intended to be tensionally pulled thereon, the first and second folding members having curved fold edges contacted by respective opposite side edges of the web when the web is pulled past the fold edges. And a web guide for guiding the web toward the fold edge, and an opening between the web guide and the fold edge, the web guide being adapted to traverse a central portion of the web as the web is pulled past the forming device; A conveyor for conveying a series of pads one by one and placing the pads on the web as the web is pulled past the forming apparatus such that the pads move over the opening with the web and cross the folding edge of the forming apparatus, and An apparatus for pressing the pad against the center of the web by forcing the pad as the pad moves across the opening, The force is sufficient to allow the web to cup and position the pad to move past the first and second folding members while at the same time sufficient to fold the side edges of the web by the respective folding edge to form a tube around the pad. Manufacturing device. Each of which is a method for manufacturing a folded interlabial pad having a fluid-absorbing body laminated with a first cover layer of fluid-permeable material, Mixing fibers of different materials, at least one of which is absorbent, Collecting the mixed fibers in a collecting station and transporting them to a forming station, Forming a continuous mixed-fiber web with the mixed fibers at a forming station, Manufacturing individual pads from said continuous mixed-fiber web and at least one first continuous cover web at a pad making station, and Folding each pad along its major axis at the folding station. 25. The method of claim 24, wherein the mixing step comprises: metering first and second amounts of first and second fibers, respectively, opening and mixing the first and second fibers, and open and mixed fibers The interlabial pad manufacturing method comprising the step of transferring to the collection station. 27. The method of claim 25, wherein opening and mixing the first and second fibers comprises subjecting these fibers to the rotational action of the beater roll, and subjecting these fibers to the rotational action of the coating roll. Method of manufacturing interlabial pads. 27. The method of claim 26, further comprising pneumatically transferring said first and second fibers from a housing with said beater roll to a housing with said coating roll. 28. The method of claim 27, further comprising the step of separating the fine fibers from the long fibers before the fibers are subjected to the rotational action of the coating roll. 25. The method of claim 24, wherein the collecting and feeding step includes transferring the open and mixed fibers to a feed chute having an inlet and an outlet, wherein the fibers are fed to the forming station through the feed chute. . 30. The method of claim 29, wherein the forming step comprises: fiberizing an initial layer of mixed fibers received from the collection station, directing fibers from the fiberized layer to a reforming conveyor, and reforming the fibers as a layer on a reforming conveyor. Interlabial pad manufacturing method comprising the step of making. The method of claim 24, wherein the pad manufacturing step, Cutting the mixed-fiber web fed through the first cutting nip to form separate absorbent bodies in the web that are arranged in position relative to each other, Laminating the at least first cover web with the absorbent body to form a laminated web, and Sealing and cutting the laminated web to form the pad. 32. The method of claim 31, wherein the cutting step is performed by a pair of cutting rolls, one of the rolls comprising a knife roll having a cutting blade on its outer surface for cutting the web. And forming a vacuum on the outer surface of the knife roll to retain the absorbent body on the roll after being cut. 33. The method of claim 32, further comprising compressing an elastically compressible insert disposed within the perimeter of the cutting blade on a knife roll when the web passes through the cutting nip, and then by the cutting blade. A method of manufacturing an interlabial pad, wherein the elasticity of the insert exerting a force on the cut absorbent body tends to push the absorbent body away from the outer surface of the roll. 34. The method of claim 33, further comprising transferring the absorbent body from the knife roll to the first vacuum transfer cylinder, wherein the pushing force applied by the insert to the absorbent body is such that the body is removed from the web during the transfer. A method of manufacturing interlabial pads that assists in being separated. 35. The interlabial method of claim 34, wherein said sealing and cutting step further comprises transferring said laminated web from a sealing station to a second cutting nip and cutting the laminated web at a second cutting nip to form a pad. Pad manufacturing method. 36. The method of claim 35, further comprising laminating a second cover web with the absorbent body to form a laminated web with an absorbent body disposed between the first and second cover webs. 25. The method of claim 24, wherein the folding step comprises: conveying a series of pads one by one along a path substantially parallel to the major axis of each pad, pressing the pads in contact with the central section of the pads as each pad is transported forward And folding the opposing side sections of each pad to face each other while the pad is pressed. 25. The method of claim 24, wherein the pads are transferred from the pad-making station to the folding station by at least one vacuum conveyor. The method of claim 24, further comprising wrapping the folded pad, The wrapping step, A web of flexible material is formed, a fold edge that is brought into contact by each opposite side edge of the web when the web is pulled past the fold edge, a web guide for guiding the web toward the fold edge, and a web. Towing past a forming apparatus having an opening between the web guide and the fold edge, the center of the web being traversed when being pulled past the apparatus; Placing a series of pads one by one on the web as the web is pulled so that the pads move across the folding edge of the forming apparatus with the web across the opening, and Forcing the pad against the center of the web by applying a force to the pad as the pad moves across the opening, the force forming the web into a cup shape to force the center of the web and the pad to first and second ends. A method for producing an interlabial pad that is positioned to move past the fold member and at the same time sufficient to fold the side edges of the web by each fold edge to form a tube around the pad. An apparatus for manufacturing a folded interlabial pad, each having a fluid-absorbing body laminated with a first cover layer of fluid-permeable material, Means for mixing fibers of different materials, at least one of which is absorbent, Means for collecting the mixed fibers at a collection station and transporting them to a forming station, Means for forming a continuous mixed-fiber web with the mixed fibers at the forming station, Means for manufacturing individual pads from said continuous mixed-fiber web and at least one first continuous cover web at a pad-making station, Means for folding each pad along the major axis of the pad, and An interlabial pad manufacturing apparatus comprising means for wrapping each pad. An interlabial pad made using the method of claim 24. Each being an apparatus for manufacturing a lamination pad having a fiber body laminated with at least one first cover layer of a fluid-permeable material, Apparatus for feeding a continuous fiber web to a first cutting station, A first cutting device for forming individual fiber bodies in the web disposed in the first cutting station, the fiber webs being fed through the first cutting nip and arranged in a predetermined position relative to each other; A rotatable first vacuum transfer cylinder for transferring the fiber body from the first cutting station to the sealing station while maintaining the fiber body in its predetermined position relative to each other, A sealing device disposed in said sealing station and defining a sealing nip, A first web supply device for feeding the at least first cover web to be laminated with the fiber body to form a laminated web and passing the laminated nip to seal the laminated web with the sealing device, and And a second cutting device disposed at a second cutting station, the second cutting device for cutting the sealed laminated web to form a pad. 43. The cutting device according to claim 42, wherein the first cutting device comprises a first cutting roll having an outer surface with a vacuum opening for holding the fiber body at the predetermined position, the cutting roll first cutting the fiber body. Laminate pad manufacturing apparatus rotatable for transferring from a nip to said first vacuum transfer cylinder. 44. The apparatus of claim 43, wherein the vacuum openings are disposed in a pattern corresponding to the position and shape of the fiber body cut in the fiber web. 45. The apparatus of claim 44, wherein the first cutting roll comprises at least one cutting blade having a perimeter corresponding to the shape of one of the fiber bodies, and an elastically compressible insert provided on the cutting roll inwardly. Wherein the insert is compressed when a fiber web is fed through the first cutting nip and the elasticity of the insert then exerts an outward force on the fiber body cut in the web by the cutting blade. Lamination pad manufacturing device. 43. The method of claim 42, wherein the first vacuum transfer cylinder has an outer surface with a vacuum opening formed therein, wherein the first vacuum transfer cylinder and the first cutting roll transfer the fiber body from the first cutting roll to the first vacuum transfer cylinder. And a first conveying nip, wherein said first vacuum conveying cylinder is rotatable for conveying towards a second conveying nip while maintaining a fiber body in said predetermined relative position. 47. The sealing device of claim 46, wherein the sealing device includes a sealing roll having a vacuum opening on its outer surface, the sealing roll from the second transfer nip to the sealing nip while maintaining the fiber body in the predetermined relative position. Lamination pad manufacturing apparatus to convey. 48. The apparatus of claim 47, wherein the seal roll and the first transfer cylinder define the second transfer nip. 48. The laminated pad of claim 47, wherein an outer surface of the seal roll is provided with a recess for receiving the fiber body transferred to the seal roll, each recess having a shape generally corresponding to the fiber body to be received therein. Device. 48. The apparatus of claim 47, wherein the first cover web is generally laminated with the fiber body in a second transfer nip. 48. The apparatus of claim 47, wherein the seal roll is rotatable to transfer the sealed laminate web to the third transfer nip while maintaining the sealed laminate web in a predetermined position on the seal roll. 52. The laminate pad of claim 51 further comprising a second transfer cylinder rotatable for transferring said third transfer nip from said third transfer nip toward said fourth transfer nip while maintaining said sealed laminated web in a predetermined position on said second transfer roll. Device. 53. The device of claim 52, wherein the second cutting device includes a second cutting roll having a vacuum opening on its outer surface, the second cutting roll holding the sealed laminated web at a predetermined position on the second cutting roll. A lamination pad rotatable to transfer from the fourth transfer nip to the second cutting nip of the second cutting station, the second cutting device operable to cut the sealed laminated web in the second cutting nip to form the pad Manufacturing device. 54. The method of claim 53, further comprising a third vacuum transfer cylinder, wherein the second cutting roll further comprises a second cutting roll and a third vacuum transfer cylinder from the second cutting nip while keeping the pad in position relative to each other. Laminate pad manufacturing apparatus rotatable for transfer to a fifth transfer nip between. 55. The apparatus of claim 54, wherein the third vacuum transfer cylinder has a vacuum opening on its outer surface and is rotatable for transferring the pad from the fifth transfer nip. 43. The apparatus of claim 42, further comprising a second web supply device for supplying a second cover web laminated with the first cover web and the fiber body to form a laminated web in which the fiber body is disposed between cover webs. And the laminate web is adapted to pass through the sealing nip for sealing thereof. 59. The apparatus of claim 56, further comprising an apparatus for applying an adhesive to the second cover web prior to the sealing nip such that an adhesive seal is made between the two cover layers when the laminated web passes through the second sealing nip. . 58. The laminated pad manufacture of claim 57, further comprising a transfer device for transferring the series of pads one by one from a third vacuum transfer cylinder to a folding station, and a folding device disposed at the folding station to fold each pad. Device. 59. The method of claim 58, wherein the transfer device comprises a vacuum conveyor, wherein the third vacuum transfer cylinder and the vacuum conveyor define a transfer nip for transferring the pad from the transfer cylinder to the vacuum conveyor, and wherein the third vacuum transfer And a cylinder is spaced apart from the vacuum conveyor by a distance not greater than the thickness of the pad in the transfer nip. 60. The apparatus of claim 59, wherein the distance at the nip is less than the thickness of the pad. 43. The method of claim 42, wherein the sealing device comprises a pair of sealing rolls, at least one of the sealing rolls for reducing the compression of the fiber body by the sealing rolls when the laminated web passes through the sealing nip. Lamination pad manufacturing apparatus which has the recess in the outer surface for accommodating the inside. 43. The apparatus of claim 42, further comprising a transfer device for transferring the series of pads one by one to a folding station, and a folding device disposed at the folding station to fold each pad, wherein the folding device comprises: A pressing member which is brought into contact with its central section when conveyed forward, and each pad when disposed on opposite sides of the pressing member and the pad is conveyed forward and folded to a position where the side sections face each other by the pressing member. Laminating pad manufacturing apparatus comprising a pair of folding members in contact with the side section of the. 63. The apparatus of claim 62, wherein at least one of the belts is a vacuum belt for vacuum gripping the pads to the belt. 43. The device of claim 42, further comprising a device for wrapping each pad after being folded at the folding station, wherein the wrapping device comprises: (a) a forming device in which a web of flexible wrapping material is tensilely pulled thereon; (i) first and second folding members having curved fold edges that are brought into contact by respective opposite side edges of the web when the web is pulled past the fold edge, (Ii) a web guide for guiding the web toward the fold edge, and (Iii) a forming apparatus comprising an opening between the web guide and the fold edge at which the center of the web is to cross when the web is pulled past the forming apparatus; (b) conveying a series of pads one by one, placing the pads on the web as the web is pulled past the forming apparatus so that the pads move with the web over the opening and past the folding edge of the forming apparatus, and (c) a device for applying a force to the pad relative to the center of the web as the pad moves across the opening; The force is sufficient to make the web into a cup shape to position the pad to move past the first and second folding members and at the same time fold the side edges of the web by the respective folding edge to form a tube around the pad. Device. Each of which is a method for manufacturing a laminated pad having a fiber body laminated with a first cover layer, Feeding the fiber web through the first cutting nip at a first cutting station, partially defined by a first rotating cutting roll having an outer surface with a vacuum opening therein, Cutting the fibrous webs fed through the first cutting nip to form separate fibrous bodies in the webs arranged in position relative to each other, A first to hold the fiber body in the predetermined relative position while rotating the first cutting roll to transfer the fiber body to the first transfer nip between the first feed nip and the rotary feed cylinder having a vacuum opening therein; Forming a vacuum in the vacuum opening in the cutting roll, Forming a vacuum in the vacuum opening in the first transfer cylinder to transfer the fiber body from the first cutting roll to the first rotary transfer cylinder while maintaining the fiber body in the predetermined relative position, Rotating the first conveying cylinder for conveying to the second conveying nip which is defined in part by a rotating first sealing roll having a vacuum opening therein while maintaining the fiber body in the predetermined relative position, Forming a vacuum in the vacuum opening in the first sealing roll to transfer the fiber body to the first sealing roll in the second conveying nip while maintaining the fiber body in the predetermined relative position, Rotating the seal roll to transport the seal body to the seal nip defined in part by the first seal roll while maintaining the fiber body in the predetermined relative position, Laminating at least a first cover with the fiber body when the fiber body is conveyed toward the sealing nip to form a laminated web, and Sealing the laminated web in a sealing nip. 66. The method of claim 65, further comprising laminating the fiber body with a second cover prior to the sealing step to form a laminated web in which the fiber body is disposed between cover webs. 67. The method of claim 66, further comprising applying an adhesive to the second cover web before the laminate web is sealed. 67. The method of claim 65, further comprising: rotating the first sealing roll to transfer the third conveying nip between the first sealing roll and the rotating second conveying cylinder while maintaining the sealed lamination web in a predetermined position, Transferring the sealed laminated web from the third transfer nip to the second transfer cylinder while maintaining the predetermined position in the predetermined position; Rotating the second transfer cylinder to transfer to a fourth transfer nip defined in part by a second rotary cutting roll having a vacuum opening therein at the second cutting station while maintaining the sealed laminated web in the predetermined position; , Forming a vacuum in the vacuum opening in the second cutting roll for transferring the sealed laminated web to the second cutting roll in the fourth transfer nip, Rotating the second cutting roll to transfer the second cutting nip defined in part by the second cutting roll while maintaining the sealed laminated web in a predetermined position on the second cutting roll, and Cutting the sealed laminated web conveyed through the second cutting nip to form the pad. 69. The second cutting roll of claim 68, wherein the second cutting roll is for transferring to a fifth transfer nip between the second cutting roll and a rotating third transfer cylinder having a vacuum opening therein while maintaining the pad in a predetermined position relative to each other. Rotating the Forming a vacuum in the vacuum opening in the third transfer cylinder to transfer the pad to the third transfer cylinder in the fifth transfer nip while maintaining the pad in the predetermined relative position; and Rotating the third transfer cylinder for transfer to the conveyor while maintaining the pad in the predetermined relative position. 70. The method of claim 69, further comprising laminating a second cover web with the fiber body prior to the sealing step to form a laminated web in which the fiber body is disposed between cover webs. 71. The method of claim 70, further comprising applying an adhesive to the second cover web before the laminate web is sealed. 72. The method of claim 71, further comprising forming a vacuum in the vacuum opening in the conveyor, and supplying a pad on a third transfer cylinder through a gap defined by the conveyor and the third transfer cylinder. Way. 70. The stack of claim 69, further comprising transferring the pads from the third transfer cylinder to the conveyor without folding the pads, transferring the pads one by one to the folding station, and folding each pad at the folding station. Pad manufacturing method. 74. The method of claim 73, wherein the folding step includes pressing the pads in contact with the central section of the pads as each pad is transported forward, and a position facing the opposite side sections of each pad while the pads are pressed. Laminating pad manufacturing method comprising the step of folding. 74. The method of claim 73, further comprising wrapping the folded pads, The wrapping step, Towing a web of flexible wrapping material onto the forming device, Transferring a series of folded pads one by one to be disposed on the web when the web is towed over the forming apparatus such that the web carries each pad past the forming apparatus, Forming a tube with a web around each pad conveyed past the forming apparatus to wrap the pad in the tube, and Sealing and cutting the tube between the pads to form a wrapper for the individual pads. 66. The method of claim 65, wherein the pad is an interlabial pad. An interlabial pad made using the method of claim 65. Each of which is an apparatus for manufacturing a lamination pad having a fiber body laminated with at least a first cover layer of a fluid-permeable material, Means for feeding the fibrous web through the first cutting nip at a first cutting station defined in part by a first rotating cutting roll having an outer surface with a vacuum opening therein, Means for cutting the fibrous webs fed through the first cutting nip to form separate fibrous bodies in the webs arranged in position relative to each other, A first to hold the fiber body in the predetermined relative position while rotating the first cutting roll to transfer the fiber body to the first transfer nip between the first feed nip and the rotary feed cylinder having a vacuum opening therein; Means for forming a vacuum in the vacuum opening in the cutting roll, Means for forming a vacuum in the vacuum opening in the first transfer cylinder to transfer the fiber body from the first cutting roll to the first rotary transfer cylinder while maintaining the fiber body in the predetermined relative position, Means for rotating the first conveying cylinder to convey the second conveying nip defined in part by a rotating first sealing roll having a vacuum opening therein while maintaining the fiber body in said predetermined relative position, Means for forming a vacuum in the vacuum opening in the first sealing roll for transferring the fiber body to the first sealing roll in the second conveying nip while maintaining the fiber body in the predetermined relative position; Means for rotating the seal roll to transport the seal body to the seal nip defined in part by the first seal roll while maintaining the fiber body in the predetermined relative position, Means for laminating at least a first cover with the fiber body when the fiber body is conveyed toward the sealing nip to form a laminated web, and And a means for sealing said laminated web in a sealing nip. An apparatus for mixing the first and second fibers, (a) an apparatus for transferring the first fiber feed to the first weighing station, (b) an apparatus for conveying the second fiber feed to the second weighing station, (c) a first metering device disposed at the first metering station for metering and releasing the first amount of the first fiber, (d) a second metering device disposed in the second metering station for metering and releasing a second amount of the second fiber, and (e) a fiber opening and mixing device for opening and mixing the first and second amounts of fibers released from the first and second metering devices, The fiber opening and mixing device, (i) a blend having a housing having an inlet for entry of the fiber and an outlet for release of the fiber, and a beater roll rotatable within the housing for opening and mixing the fiber and releasing through the outlet Opener, and (Ii) a fine comprising an inlet for receiving fibers from the blend opener outlet, a housing having an outlet, and a coating roll rotatable within the housing for further opening and mixing the fibers to release through the outlet; A fiber mixing device having an opener. 80. The fiber mixing apparatus of claim 79, wherein the blend opener and the fine opener are connected by a pneumatic conveyor system to transfer the fibers from the blend opener to the fine opener. 81. The fiber mixing apparatus of claim 80, wherein the pneumatic conveyor system is operable to separate the fine fibers from the long fibers and to feed the long fibers to the fine openers. 80. The fiber of claim 79 as an inlet for receiving mixed fibers from said fine opener, an outlet, an accumulation chute between said inlet and outlet for accumulating fiber columns, and said fibers from said column through said outlet as layers of fibers. And a feed chute having a feeding means at said outlet for feeding. 83. The fiber mixing device of claim 82, further comprising a fiberizing device for breaking the layer into individual fibers and a reforming conveyor on which the individual fibers are stacked as a reformed layer of mixed fibers thereon. An apparatus for mixing the first and second fibers, Means for conveying the first fiber feed to the first weighing station, Means for conveying a second fiber feed to a second weighing station, Means for metering and releasing a first amount of first fibers, Means for metering and releasing a second amount of second fibers, and And means for opening and mixing the first and second amounts of fibers released from the means for metering and releasing the first and second amounts of fibers. 85. The apparatus of claim 84, wherein the means for opening and mixing the fibers are: A blend opener comprising a housing having an inlet for entry of the fiber, an outlet for release of the fiber, and a beater roll rotatable within the housing for opening and mixing the fiber to release through the outlet; and A fine opener comprising an inlet for receiving fibers from the blend opener outlet, a housing having an outlet, and a coating roll rotatable within the housing for further opening and mixing the fiber to release through the outlet Fiber mixing device. 86. The fiber mixing device of claim 85, further comprising means for entraining the blended fibers in an air stream to transfer from the blend opener to the fine opener. Is a method of mixing the first and second fibers, Conveying the first fiber feed to the first weighing station, Conveying a second fiber feed to a second weighing station, Metering out the first amount of the first fiber, Metering and releasing a second amount of second fibers, Conveying the first and second amounts of fibers to a blend opener, Opening the first and second amounts of fibers and mixing them with a first rotatable roll in the blend opener, Entraining the blended fibers in an air stream to transfer from the blend opener to the fine opener, and Further opening the fiber to mix with a second rotatable roll in the fine opener. 88. The method of claim 87, further comprising separating the fine fibers from the long fibers of the mixed fibers before opening and mixing the mixed fibers in the fine openers. 88. The method of claim 87, further comprising substantially separating the mixed fibers from the air stream prior to opening and mixing in the fine opener. 88. The method of claim 87, further comprising: feeding mixed fibers as an initial layer of mixed fibers, crushing the initial layer into tufts and individual fibers at a fiberization station, and moving the teaspoon and individual fibers. And reforming as a reformed layer of blended fibers on a conveyor. 87. An interlabial pad made using the method of claim 87. Each of them is a system for folding the interlabial pad with its major axis, A conveyor for conveying a series of said pads one by one to a folding station, and A folding device for folding each pad disposed in the folding station and conveyed forward along the main axis; The folding device, A pressing member adapted to contact a central section of the pad extending generally parallel with the main axis when each pad is moved forward, and A pair of pairs disposed on opposing sides of the urging member and brought into contact with the side sections of the pads on the opposing sides of the main shaft when the pads are transported forward and folded by the urging members to their side sections facing each other. An interlabial pad folding system comprising a folding member. 93. The apparatus of claim 92, wherein at least one adhesive spot is applied to at least one side section of each pad prior to folding to secure the pad in a folded state by the adhesive when the two side sections are folded to the facing position. Interlabial pad folding system further comprising. 94. The rotatable disk of claim 93, wherein the urging member comprises a rotatable disk having a plurality of openings disposed at spaced intervals around the edge and the peripheral edges, each of the openings of the pad at the at least one adhesive spot site. An interlabial pad folding system that is sized and positioned to allow side sections to contact each other. 95. The conveyor of claim 92, wherein the conveyor comprises a center belt and two side belts on opposite sides of the center belt, the belt defining a first slot between the center belt and one side belt and the other side of the center belt. A generally parallel, generally coplanar, spaced upper reach defining a second slot between the side belts, the urging member is spaced from the center belt to form a gap and a pad is conveyed through the gap Contact the center section of each pad to keep the pad pressed on the center belt when the folding member extends through each slot between the belts as the pad moves through the gap to fold the side section of the pad. Interlabial pad folding system. 95. The interlabial pad folding system of claim 95, wherein the urging member is a rotatable disk having a peripheral edge spaced from the center belt to form the gap. 95. The apparatus of claim 95, wherein the folding member comprises a pair of rotatable disks, each disk having ramps formed at intervals around its periphery, the ramps having the pads conveyed through the gaps. An interlabial pad folding system, wherein the interlabial pad folding system is adapted to contact the pads to gradually fold the side sections of each pad. 95. The interlabial pad folding system of claim 95, wherein at least one of the belts is a vacuum belt for vacuum gripping the pads to the belt. 95. The interlabial pad folding system of claim 92, wherein the conveyor is a vacuum conveyor for vacuum gripping the pads to the conveyor. Each of them is a system for folding the interlabial pad with its major axis, Means for conveying a series of said pads one by one to a folding station, and Folding means for folding each pad along said major axis when the pad is conveyed forward, The folding means, Pressing means for contacting the central section of each pad extending generally parallel to the main axis when the pad is conveyed forward, and And means for contacting the side sections of the pads on opposite sides of the main axis when the pads are transported forward and folded by the pressure member to their side sections facing each other. How to fold the interlabial pad, Conveying a series of said pads one by one in a direction along the major axis of each pad, to a folding station, Contacting the central section of each pad extending generally parallel to the main axis with the pressing means when the pad is conveyed forward, and And folding the side sections of the pad into positions facing each other by bringing the side sections of the pad into opposing sides of the main axis when the pad is conveyed forward and in contact with the urging member. 102. The method of claim 101, wherein applying at least one adhesive spot to at least one side section of each pad prior to folding to secure the pad in a folded state by the adhesive when the two side sections are folded to the facing position. The interlabial pad folding method further including. 107. The apparatus of claim 102, wherein the central section of each pad is contacted by a pressing member comprising a rotatable disk having a plurality of openings disposed at spaced intervals around the edge and a peripheral edge, each of the openings being: The interlabial pad folding method being sized and positioned such that side sections of the pad are in contact with each other at the at least one adhesive spot site. 107. The apparatus of claim 103, wherein the side sections are contacted by a folding member that includes a pair of rotatable disks, each disk having lamps spaced around its perimeter, the lamps having sides of each pad. How to fold the interlabial pad, which is supposed to fold the section gradually. 107. The method of claim 103, wherein conveying the series of pads comprises vacuum holding the pads on a conveyor. An interlabial pad made using the method of claim 101. An apparatus for forming a continuous web with a layer of mixed fibers, A mixing device for mixing the first and second fibers, An inlet, an outlet for receiving a feed of the mixed fibers, an accumulating chute disposed between the inlet and the outlet, for accumulating a column of mixed fibers, and an outlet arranged at the outlet to direct fibers from the column through the outlet A collecting and feeding device disposed in the fiber collecting station, the feeding means for feeding the forming station as an initial layer of mixed fibers, Fiberizing apparatus for crushing the initial layer into teaspoons and / or individual fibers, and And a reforming device having a reforming conveyor stacked thereon as a reformed layer of mixed fibers of the individual fibers. 108. The web forming apparatus of claim 107 wherein the initial layer is substantially uniform in width and thickness. 107. A web forming apparatus according to claim 107, wherein said supply means feeds the fibers as an initial layer of mixed fibers having a density of 0.005 to 0.050 g / cc. 107. A web forming apparatus according to claim 107, wherein said supply means feeds the fibers as an initial layer of mixed fibers having a density of 0.010 to 0.030 g / cc. 107. A web forming apparatus according to claim 107, wherein said supply means feeds the fibers as an initial layer of mixed fibers having a density of 0.013 to 0.019 g / cc. 108. The apparatus of claim 107, wherein the reforming apparatus comprises: an air chamber having an inlet for receiving the individual fibers and an outlet adjacent the reforming conveyor, and an air stream moving toward the reforming conveyor to generate the fibers to convey the fiber A web forming apparatus comprising an air system for directing upwards. 118. The web forming apparatus of claim 112, wherein the reforming apparatus further comprises an apparatus for compressing the reformed layer into a continuous web of a predetermined thickness. A method of forming a continuous mixed-fiber web with a layer of mixed fibers, Mixing the first and second fibers, Collecting a feed of the mixed fiber, Feeding the fibers from the feed as an initial layer of mixed fibers, Crushing the initial layer into teaspoons and / or individual fibers at a fiberizing station, and Reforming the individual fibers as a reformed layer of mixed fibers on a moving conveyor. 118. The method of claim 114, wherein the initial layer is substantially uniform in width and thickness. 118. The method of claim 114, wherein the initial layer of mixed fibers has a density of 0.005 to 0.050 g / cc. 118. The method of claim 114, wherein the initial layer of mixed fibers has a density of 0.010 to 0.030 g / cc. 118. The method of claim 114, wherein the initial layer of mixed fibers has a density of 0.013 to 0.019 g / cc. 119. The method of claim 114, wherein the feeding step comprises compressing fibers to form the initial layer. 118. The method of claim 114, wherein the fiber is directed to the conveyor by an air chamber and an air stream in the air chamber flowing toward the conveyor. 118. The method of claim 114, wherein the fibers in the reformed layer are oriented irregularly. 119. The method of claim 114, further comprising compressing the reformed layer to create a continuous web of predetermined thickness. 114. An interlabial pad made using the method of claim 114. An apparatus for forming a continuous web with a layer of mixed fibers, Means for mixing the first and second fibers, Means for collecting a supply of the mixed fiber, Means for feeding the fibers from the feed as an initial layer of mixed fibers, Means for crushing the initial layer into teaspoons and individual fibers at a fiberizing station, and Means for reforming said individual fibers as a reformed layer of mixed fibers on a moving conveyor. Is a device for wrapping pads, A forming device in which a web of flexible wrapping material is intended to be tensionally pulled thereon, the first and second folding members having curved fold edges contacted by respective opposite side edges of the web when the web is pulled past the fold edges. And a web guide for guiding the web toward the fold edge, and an opening between the web guide and the fold edge, the web guide being adapted to traverse a central portion of the web as the web is pulled past the forming device; A conveyor for conveying a series of pads one by one and placing the pads on the web as the web is pulled past the forming apparatus such that the pads move over the opening with the web and cross the folding edge of the forming apparatus, and An apparatus for pressing the pad against the center of the web by forcing the pad as the pad moves across the opening, The force is sufficient to force the web into a cup shape to position the pad to move past the first and second folding members while at the same time folding the side edges of the web by the respective folding edge to form a tube around the pad. . 126. The pad wrapping apparatus of claim 125, further comprising a device for sealing and cutting the tube to form a separate wrapper for the pad. 126. The pad wrapping apparatus of claim 125, wherein the force applied to the pad is sufficient to stretch the web such that the web tightly wraps around the pad when the tube is formed. 126. The pad wrapping apparatus of claim 125, wherein the force-applying device includes an inclined surface contacted by the pad to press the pad to the center of the web. 129. The pad wrapping apparatus of claim 128, wherein the inclined surface is provided with one or more air holes for directing air from an air source to form an air film between the inclined surface and the pad. 126. The pad wrapping apparatus of claim 125, wherein the force-applying device is movable in the web moving direction to apply a pushing force in the web moving direction relative to the pad. 131. The pad wrapping apparatus of claim 130, wherein the force-applying device includes an inclined surface that contacts the pad to press the pad to the center of the web. 131. The pad wrapping apparatus of claim 130, wherein the force-applying device comprises an endless belt having an inclined reach disposed to contact the pad. 126. The pad wrapping apparatus of claim 125, wherein the pad is elastically compressible and the force applied to the pad is sufficient to elastically compress the pad. 138. The pad wrapping apparatus of claim 133 wherein the force is sufficient to compress the pad to a thickness in the range of 50 to 99% of the uncompressed pad thickness. 126. The apparatus of claim 125, wherein the folding member comprises upper and lower folding plates having spaced generally parallel opposing surfaces that define a relatively narrow gap that extends in the direction of web movement when the web is pulled past the forming apparatus. And the gap is adapted to receive the at least one side edge of the web when the web is folded to form the tube. 126. The web of claim 125, wherein the web guide comprises a wall in contact with the web, the wall being angled with respect to the plane of the opening, the side edge tapering towards a base edge and a vertex, and the vertex from the vertex. A pad wrapping device having a tongue extending toward an opening. 136. The apparatus of claim 136, further comprising a pair of notches in the wall extending from the vertex toward the base edge on the opposite side of the tongue, the portion of the web being pulled over the wall and the tongue. Pad wrapping device deformed into the notch. 126. The pad wrapping apparatus of claim 125, wherein the web guide and the folding member are formed as a single piece of bent sheet metal. 126. The apparatus of claim 125, wherein the folding member folds the opposing side edges in a face-to-face overlapping relationship, wherein the wrapping device applies adhesive to one web side edge such that an adhesive bond is formed therebetween when the side edges overlap. A pad wrapping apparatus further comprising an adhesive applicator for applying. 141. The pad wrapping apparatus of claim 139 wherein the adhesive applicator is operable to apply adhesive to the one side edge at a position upstream from the fold edge. 126. The pad wrapping apparatus of claim 125, wherein said pad is an interlabial pad. Pad wrapping method, A web of flexible wrapping material, a folding edge which is brought into contact by each opposite side edge of the web when the web is pulled past the folding edge, a web guide for guiding the web towards the folding edge, and the web Towing past the forming apparatus having an opening between the web guide and the fold edge, the center of the web being traversed when being pulled past the forming apparatus; Placing a series of pads one by one on the web as the web is pulled so that the pads move across the folding edge of the forming apparatus with the web across the opening, and Forcing the pad against the center of the web by applying a force to the pad as the pad moves across the opening, the force forming the web into a cup shape to force the center of the web and the pad to the first and second folding members. Sufficient to position to move past and simultaneously fold the side edges of the web by each folding edge to form a tube around the pad. 142. The method of claim 142 further comprising sealing and cutting the tube to form a separate wrapper for the pad. 142. The method of claim 142, wherein the tube is formed around each pad such that opposite side edges of the web overlap each other. 142. The method of claim 142, wherein the pressing step includes moving the pad against a surface that is inclined with respect to the direction of web movement to press against the web. 145. The method of claim 145, wherein the pressing step further comprises forming an air film between the inclined surface and the pad. 142. The method of claim 142, wherein the force applied to each pad is sufficient to elastically stretch the web such that the web tightly wraps around the pad when the tube is formed. 142. The method of claim 142 wherein the pad is elastically compressible and the force is sufficient to elastically compress the pad. 148. The method of claim 148, wherein the force is sufficient to compress the pad to a thickness in the range of 50 to 99% of the uncompressed pad thickness. 142. The method of claim 142, wherein the folding member folds the opposing side edges in a face-to-face overlapping relationship, wherein the method applies an adhesive to one web side edge such that an adhesive bond is formed therebetween when the side edges overlap. The pad wrapping method further comprising the step. 151. The method of claim 150, further comprising applying the adhesive to the one web side edge at a position upstream from the fold edge. Pad wrapping device, A web of flexible wrapping material, a folding edge which is brought into contact by each opposite side edge of the web when the web is pulled past the folding edge, a web guide for guiding the web towards the folding edge, and the web Means for pulling past the forming apparatus having an opening between the web guide and the fold edge, the central portion of the web being traversed when being pulled past the forming apparatus; Means for placing a series of pads one by one on the web when the web is towed to move the pads across the opening with the web past the folding edge of the forming apparatus, and And means for applying a force to the pad against the center of the web as the pad moves across the opening, the force forming the web into a cup shape to force the center of the web and the pad to the first and second folding members. A pad wrapping apparatus, sufficient to position to move past and simultaneously fold the side edges of the web by respective folding edges to form a tube around the pad. An interlabial pad made using the method of claim 142.